DE102015224885A1 - Procedures for placement of patches and manufactured articles - Google Patents

Abstract

The present invention relates to a method for producing sports articles, in particular shoes, comprising the steps of providing a plurality of components in one of a plurality of predefined shapes and placing the plurality of components on a two-dimensional or three-dimensional support surface for producing the sports article or a Part of it.

Description

1. Technical area

The present invention relates to a method and an apparatus for the production of sports articles, in particular shoes and sports articles, in particular a shoe or a part thereof, which has been produced by this method.

2. State of the art

Every year, the manufacture and sale of sporting goods leads to a significant number of new product designs and product features. It is essential for a manufacturer to quickly understand the latest market developments and / or to present a range of innovative products themselves. Sports articles in this context include, for example, shoes, textiles and accessories in a variety of models, designs, production possibilities, colors, sizes, etc. Nowadays, most new products are digitally designed, modeled and tested in a first step, using three-dimensional computers supported design and / or finite element analysis systems ("3D CAD" / "FEA").

However, a prototype must first be manufac- tured manually based on the digital design to bring a new product to market. This is typically done in factories that may be located elsewhere than the design department responsible for product design. Only after delivery and receipt of the real-life examples are the product designers able to further optimize their digital designs and then send them back to the factories. This process is repeated until the embodiments can meet the desired functionality, appearance, cost, and quality requirements, and be released for mass production in the factories. As a result, it can often take several weeks and up to months or even years to get a result.

Furthermore, the entire development chain is very inflexible. Accordingly, the manufacturer can only react slowly to short-lived fashion trends and market demand. The advantage in terms of speed gained by using CAD / FEA systems for development is lost, at least in part, due to the overall slow production processes of factories around the world.

A manufacturing process known in the art that addresses this general problem is schematically illustrated in FIG 1 shown. As shown, the known process begins by unwinding a composite tape on a roll, which is then cut into individual strips on a conveyor belt (step 1). The strips are then picked up by a robot equipped with a gripping device (step 2). A meltable layer of each strip is then activated by heat to provide adhesion (step 3), and the strip is applied to a two-dimensional or three-dimensional support surface (steps 4a and 4b). The processing of a plurality of strips in this way allows the construction of a complex product, including stratification of the strips. While the known method makes the manufacture more efficient and flexible to a certain extent, the result still has room for improvement in the product since the majority of strips typically still need to be processed in further, possibly manual, manufacturing steps to arrive at the desired product reach.

Further production techniques for the production of products based on individual material components and corresponding gripping devices are described, for example, in US Pat US 8,567,469 B2 . US 2014/0134378 A1 . US 5,427,518 . US 8,371,838 B2 . US 7'182'118 B2 and US 2005/0061422 A1 disclosed. However, these approaches have the disadvantage that the properties of the resulting product are very limited and that the preparation of complex products using these approaches requires extensive additional, possibly manual manufacturing steps.

It is therefore the object of the present invention, based on the prior art, to provide improved production methods and means of production which enable directly, at least partially automatically and preferably on site a plurality of different prototypes, end products or the like of individual material components (also referred to as "patches "Designated) in a particularly flexible manner. In this context, it is a further object of the invention to make fast and particularly flexible design and / or functional changes to the manufactured products. Increasing the ability to change designs of sporting goods in a short time frame improves the responsiveness to the needs of the market and / or customers.

3. Summary of the invention

According to a first aspect of the present invention, this object is at least partially fulfilled by a method for the production of sports articles, in particular of shoes. In one embodiment, the method includes the steps of providing a plurality of components in one of a plurality of predefined shapes, and placing the plurality of components on a two-dimensional or three-dimensional support surface to produce the sports article or a portion thereof.

Although the preferred embodiments of the invention are described below with respect to athletic shoes, the present invention is not limited to these embodiments. Rather, the present invention may also be used to advantage for other types of sporting goods, namely sportswear such as shirts, pants, gloves, etc., as well as sports equipment such as balls, rackets, hockey sticks, and batons.

Furthermore, it is fundamentally conceivable that embodiments of the method according to the invention are essentially automatic. However, a degree of manual support work may still be required. In other words, embodiments of a method according to the invention may be practiced, at least primarily, by robots, robotic systems or automated systems, and / or the embodiments may further include some amount of human (supporting) work. The robots, robotic systems or automated systems may continue to be equipped with hardware and / or software specifically adapted for the particular task, or they may be general-purpose devices.

Advantageously, the method according to the invention makes it possible to produce a sports article or a part thereof in a particularly flexible manner. This is due to the fact that the sporting article may preferably be composed substantially automatically of individual components in one of a plurality of predefined forms. This enables the manufacture of sports articles that have a wide variety of properties due to the placement and shape of the components used, which is a notable improvement over the prior art approaches that use only strips of material of a predefined length. It is to be understood that the two-dimensional or three-dimensional support surface to which the components are applied to form the product may either form part of the final product (for example, if the support surface itself is an element of the final product) or the composite elements of FIG Carrier surface can be removed (for example, when the support surface is a tray, a fabric, a carrier, a soluble base layer or a shoe last).

In some cases, the support surfaces may be formed of materials that have low thermal conductivity. In some cases, it may be useful for the materials used as support surfaces and / or surfaces on which consolidation takes place, if they have a thermal conductivity of less than 25 watts per meter per Kelvin (W · m ^-1 · K) ^-1 ). For example, in some embodiments, it may be desirable to use a material having a thermal conductivity of about 1 watt per meter per Kelvin (W · m ^-1 · K ^-1 ). Furthermore, there may be the case that surfaces used for transporting materials on which consolidation can take place have low thermal conductivity. For example, a glass plate can be used when consolidating a two-dimensional upper.

In some cases, it may be desirable to build a support surface, a surface on the consolidation, and / or a transport device so as to obtain different thermal conductivities in different areas of the surface on which the pads and / or components rest. This allows the controlled application of heat in certain areas of patches and / or components.

Preferably, the plurality of components comprises at least one patch, that is, a piece of material. The composition of a sports article or a part thereof of a plurality of patches makes it possible to provide a large number of different desired properties of the sports article, such as reinforcement, breathability, flexibility, grip and / or many others, as will be explained below. Additionally or alternatively, the plurality of components may include other elements, such as a structural member (eg, a heel cup, a cage, a support structure, a tube, or a band), an outsole component (eg, a bolt, a tab, an outsole, or an outsole member). , an eyelet reinforcing member, a midsole member, a locking mechanism (such as laces, a lace structure, or a hook and loop fastener system), a bar code, a quality control code ("QC Code"), an electrical component (eg, a near field communications (NFC) chip Radio frequency identification (RFID) chip, motor, chipset, antenna, microchip, interface, light source, line, circuit, energy harvesting element and / or battery, etc.), a sensor (eg, a pressure sensor such as a comfort pressure sensor, a strain sensor, an accelerometer, a magnetic field strength meter or a location sensor such as a Global Positioning System (GPS) sensor, a mechanical component, or a combination thereof. As can be seen, practicing the invention in this aspect enables the production of very complex sporting goods in an efficient and flexible manner.

According to one aspect of the present invention, the step of providing a plurality of components includes the use of a configurable cutter for cutting a plurality of patches. The cutting device may include at least one of: a laser source, a knife, a die, a water nozzle, a heating element, a solvent, or any combination thereof. Accordingly, the patches can be produced directly during operation during the manufacturing process. Additionally or alternatively, at least one of the patches may be provided in pre-cut form.

For example, the configurable cutting device may comprise a laser source and means for controlling a laser beam emitted by the laser source, the means preferably comprising at least one mirror. Accordingly, this enables a particularly correct and accurate cutting of patches, since the laser beam emitted from the preferably stationary laser can be guided more effectively by means of the mirror (s).

Furthermore, laser cutting can be used to apply patterns to the patches. For example, a laser can be used to engrave a pattern on the patch. In particular, slats, lines and / or / different shapes can be engraved on the patch.

In another aspect of the present invention, the method includes the further step of consolidating components using heat and / or pressure over a defined period of time. Accordingly, after a plurality of patches and / or other components have been placed on the support surface in the method discussed above, a so-called "consolidation" may be performed by applying heat and / or pressure to the plurality of patches. This can take one or two steps, depending on the materials used. In one embodiment, a flexible membrane, such as a stretchable silicone skin that may initially be stretched on a frame, is used to consolidate the patches and / or other components into an article, such as a shoe. By means of the consolidation step, the method of the invention can be carried out without the use of a rigid mold or a rigid negative mold component.

Consolidation preferably takes place at a temperature in a range of 40 ° C to 240 ° C. Furthermore, some constructions may be performed at temperatures in the range of 55 ° C to 200 ° C. Furthermore, there may be constructions in which consolidation is performed at temperatures in the range of 100 ° C to 180 ° C. The pressure during consolidation can be controlled so that the pressure is in the range of 0.1 bar to 10 bar above the atmospheric pressure. In some cases, the pressure can be controlled during consolidation in a range between 1.1 bar and 4 bar. Furthermore, the pressure during the consolidation can be controlled in a range between 1.5 bar and 2 bar. For example, using very thin patches made of, for example, tape, less time and pressure may be applied, such as 180 ° C at 1.5-2 bars over a period of 60-90 seconds.

Pressure that can be used to consolidate the patches and / or other components can be an overpressure applied to the flexible membrane. Accordingly, pressure can be applied to the flexible membrane which has been placed over the patches and / or other components to be consolidated. In some cases, negative pressure can be used to consolidate materials. For example, a vacuum can be applied to the patches to place the flexible membrane over the patches and to consolidate the patches.

As a result, the manufacturing process is greatly simplified while the manufactured article has improved resistance at the same time due to the consolidation of the plurality of individual patches and / or other components. The consolidation step can be a completely automated step.

In some cases, a flexible membrane [member] can be placed on the majority of patches. In one aspect, this at least one flexible membrane [member] is substantially flat before being applied to the plurality of patches of material. Such a substantially flat, flexible membrane is particularly well suited when the support surface is two-dimensional, such as For example, a work surface, a table or a flat surface material. But it can also be applied to three-dimensional support surfaces.

Alternatively, the flexible membrane may be preformed to at least partially conform to the contour of the sports article to be made. This allows a particularly good fit of the flexible membrane, in particular when the patches are placed on a three-dimensional support surface, such as a last for a shoe to be manufactured.

In any case, as noted above, the flexible membrane may include, for example, silicone. Consolidation through the use of a flexible membrane may involve the application of pressure and / or heat to the flexible membrane.

The method may include the further step of extracting air from the plurality of patches of the material having the flexible membrane applied thereon. For example, the support surface may be on a worktable provided with holes through which a vacuum can be produced on the underside of the article being manufactured. The withdrawal of air from the composite patches before, during, and / or the superimposition of the flexible membrane advantageously improves the consolidation of these components.

Furthermore, heat can be applied to the plurality of patches of the material with the membrane [member] applied thereon. For example, the above-mentioned work surface may be a heat table, so that the adhesive properties of the patch are enhanced and not only the patches are consolidated in relation to each other. Heat may be used before, during, and / or after the use of the flexible membrane to apply pressure to the patches. For example, heat may be applied to the majority of the patches prior to applying pressure.

In some cases, heat can be applied to the patches through the flexible membrane [member]. Accordingly, the flexible membrane [member] can provide heat and pressure to consolidate the patches.

In another aspect of the invention, the step of providing a plurality of components may comprise the steps of providing material from a spool, a belt, a tray and / or a stack to a transport device; Cutting the plurality of components from the material using a cutting device and automatically removing excess material from the transport device. For example, materials may be processed by providing the material using a first coil, cutting out the majority of the components using a cutting device, and preferably removing the excess material using a second coil. Such a "coil-to-coil" process that results in the automatic removal of excess material after cutting may be fully or partially automatic to bring about significant efficiency improvements.

In some aspects of the invention, at least one of the plurality of components and / or the support surface may include a coupling mechanism such that an electrostatic force, a chemical, and / or a mechanical seal is formed between at least two of the plurality of components or a portion of the sporting article. For example, the coupling mechanism may include at least one electrostatic force, a hot melt adhesive, a solvent based process, a hook and loop fastener, or any combination thereof.

In another aspect, the method includes the step of activating at least one of the components, preferably by heating, to obtain a robust construction of the patches and / or other components. The activation step may take place before the respective last one patch / component is applied to the carrier surface and / or after a plurality of patches / components have been applied to the carrier surface. For this purpose, the adhesive component preferably comprises a hot melt adhesive.

In one embodiment, the step of placing the plurality of material patches on the support surface takes place by means of an automatic gripping device that enables significant automation of the process. The gripping device may comprise one or more grippers, which may be arranged modular. Accordingly, it is possible to provide a gripping device in a flexible manner capable of processing any kind of patches, regardless of their composition or shape.

As mentioned above, the two-dimensional support surface may comprise a work surface (from which the article is removed after production), or a substantially flat base material, such as a knit material or a midsole (which becomes part of the manufactured product). Similarly, a three-dimensional support surface may comprise a working form, such as For example, a last, or a base material that lies on the work form.

The patch material used in the embodiments of the invention may include metal, polymer, such as polyurethane, for example, thermoplastic polyurethane, nylon, or other polymers known in the art, foams, such as expanded foam, particulate foam, textile material, e.g., a knit , Nonwoven, woven or similar material, hook and loop material, synthetic leather, coated material, transparent material, dyed material, printed material, structured material, natural fiber, for example silk, wool, hair such as camel hair, cashmere , Mohair, or the like, cotton, flax, jute, kenaf, ramie, rattan, hemp, bamboo, sisal, coconut fiber, or the like, leather, suede, rubber, a woven structure, or any combination thereof.

The plurality of patches may be arranged in a manner that a particular area of an article has one or more properties. Properties of interest to patch materials may include, but are not limited to reinforcement, breathability, durability, traction, flexibility, thermoplasticity, adhesion, traction, water repellency, water resistance, electrical conduction, electrical resistance, or any combination thereof (see the examples in the detailed description below).

Furthermore, the method may include a step for providing at least one further element in addition to the plurality of patches, in particular at least one structural element such as a heel cap, a cage, a support structure, a tube or a band, at least one outsole component, such as a bolt Tab, an outsole or outsole member, at least one eyelet reinforcing member, at least one midsole member, at least one fastener mechanism such as laces, a lace structure, or hook and loop fastener systems, or any combination thereof. As a result, the production of a final, complex sports article can be largely automated.

In some cases, a cover layer may be placed on the majority of the patches and / or components. The placement of the topcoat may occur before, after, and / or during the consolidation process. Covering layers for use with patched articles may include, but are not limited to, films, films, polymers, membranes, synthetic materials, natural materials, and / or any combination thereof.

A cover layer may in some instances provide a relatively tight and glove-like fit for an article made partially or completely from patches and / or other components. If the article is designed as a shoe, for example a football boot, the cover layer can improve the ball feel, ball control and the effect of a ball that is kicked with the shoe, so that the flight phase of the ball has a greater curvature. Typically, coversheets can provide the article with functional properties. For example, a topcoat may be used to protect against wear, abrasion, or water, to control air and / or water permeability, to reduce extensibility, to control other predetermined properties, and combinations of the foregoing.

Using image processing means in the form of, for example, one or more cameras and corresponding image recognition software, at least one of the plurality of patches and / or components may be identified as being applied to the carrier surface, providing automatic identification and corresponding correct placement of the / r Patch (es) and / or components allows.

Furthermore, it is conceivable that the method enables an at least partially automatic "idea-to-product" process. To this end, the method may include the steps of receiving a design specification of the sports item to be manufactured, in particular a computer aided design (CAD) file which is, for example, the result of a purchase order and automatically generating a production plan based on the design specification and performing the Step of placing the plurality of components according to the production plan. The production plan can be adapted in a 2D version by comparing a reference carrier surface with the actual carrier surface and adjusting the position of the robot to the patches to be placed. Because of this adaptability, the support surface need not be placed with a specific orientation.

In a further aspect, the method of the invention may include identifying the carrier surface by means of image processing means and providing position data to a controller to adjust the placement of at least one of the plurality of components. An optical system can recognize the parts taking into account the contours of the parts. If the contour is distorted, feedback can be sent to the controller be adapted to the arrangement of the components. Accordingly, many patches can be placed with high patch placement accuracy.

The automatic generation of a production plan based on the design specification may further include generating a cloud of points to place at least one of the plurality of components on the support surface. In particular, point clouds can be used to arrange the components on 3D bars / uppers.

In a further aspect of the invention, any of the foregoing methods may be performed in an apparatus provided for practicing one embodiment of an inventive method. Within such a device, a plurality of differently designed shoes or other sporting goods can be produced almost fully automatically, as already mentioned above.

In particular, the method can be carried out within a mobile container. In particular, the container is at least partially transparent. This allows the implementation of the methods of the invention directly "on-site", for example at sports events or in a retail outlet, etc. A buyer can then so a desired shoe model directly on site with the device "put together", or even in advance via the Internet or The like, which model is then produced by the portable manufacturing device. If the container is partially transparent, the customer may even watch how the shoes or articles are made. Furthermore, the process could be recorded by video and transmitted live in digital media networks / channels.

A further aspect of the present invention relates to a sporting article, in particular a shoe or a part thereof, which has been produced using an embodiment of the method according to the invention.

As mentioned above, in this regard, it is possible to individually personalize and modify each of the plurality of shoes produced, for example, based on the design of a development designer, the anatomy of the wearer, or even based on customer requests made, for example, via the Internet be received.

In some embodiments, it is possible to use an analysis tool including, but not limited to, printing plates, glass cameras, barefoot pressure distribution, pressure distribution sensing insoles, printing paper such as carbon or ink microcapsule based paper, 3D scans, stress maps (e.g. Aramis system data ), Step analysis, movement analysis, sweat card, foot shapes to determine the needs of a particular athlete. The output of one or more of these analysis tools may be used to develop designs customized for the athlete. For example, data collected using the analysis tools may be used to personalize soles, midsoles, topsets, and / or combinations thereof develop.

For athletes, areas in the outer and / or midsole can be developed that meet the athlete's needs, such as functional properties such as cushioning, abrasion resistance, traction, etc. For example, a forefoot runner may not need a solid rubber outsole. By reducing the number of rubber elements, the weight of the shoe can be reduced. Again, it should be expressly understood that the particular embodiments of an inventive method, embodiments of an inventive apparatus, and / or embodiments of an inventive shoe having design capabilities and embodiments as disclosed herein may be combined with each other depending on the particular requirements. Individual options and design options described herein may be disregarded insofar as they appear to be deemed appropriate for the particular method, device or shoe to be produced, although the resulting embodiments are still part of the invention.

4. Brief description of the drawings

Presently preferred examples and embodiments of the present invention will be explained in the following detailed description with reference to the following figures:

1 : A method for patch placement production according to the prior art;

2a -F: various shapes that are suitable for patches according to the invention;

3 -A-t: Various illustrative examples of patches according to the invention;

4 : An exemplary configuration of patch-engraved louvers according to the invention;

5 : An exemplary configuration of an engraving pattern on a patch according to the invention;

6 : An embodiment of a method according to the invention for the manufacture of a sports article;

7 : An exemplary use of a solid plate to provide heat and pressure for patches according to the invention;

8a -C: alternatives for using a flexible membrane [member] according to the invention;

9 - 12 : Further exemplary methods according to embodiments of the invention;

13 - 16 Exemplary consolidation process according to embodiments of the invention;

17 : A "spool-to-spool" process for the automatic removal of excess material according to an embodiment of the invention;

18 : An example of multi-step cutting of patches according to an embodiment of the invention;

19 A modular gripping device according to an embodiment of the invention;

20 : An automated, computer-aided idea-to-production process according to an embodiment of the invention;

21 : Examples of pattern recognition according to an embodiment of the invention;

22a C: Sample graphical user interfaces for pattern recognition according to an embodiment of the invention;

23a -D: exemplary production cells according to an embodiment of the invention;

24 - 26 Exemplary design files according to embodiments of the invention;

27 - 33 : Illustrative examples of algorithms for the manufacture of an article according to embodiments of the invention;

34 : Examples of patches according to an embodiment of the invention;

35 : Overview of athletic shoes made using a method according to an embodiment of the invention;

36a -C: examples of patch materials according to embodiments of the invention;

37 : An example of a sports shoe made using a method according to an embodiment of the invention;

38 : An example of a sports shoe made using a method according to an embodiment of the invention;

39 : An example of a sports shoe made using a method according to an embodiment of the invention;

40 : An example of a sports shoe made using a method according to an embodiment of the invention;

41 : An illustrative example of a shoe upper construction according to the invention;

42 - 44d : Further examples of shoes according to the embodiments of the invention;

45 Exemplary application of patches on shoes according to the embodiments of the invention;

46 - 52 : Further illustrative examples of footwear according to the embodiments of the invention;

53 : An embodiment of a method according to the invention for the manufacture of a sports article;

54 An example of outsole elements and examples of configurations of outsole elements on an outsole made using a method according to the invention;

55a -B: An example of a gripping device arranged using a method according to the invention outsole elements on a shoe;

56 : An example of a gripping device that places midsole elements on a shoe using a method according to the invention;

57 - 59 : Further illustrative examples of footwear according to the embodiments of the invention;

60 : An example of a shirt made using a method according to an embodiment of the invention;

61 : An example of a brassiere made using a method according to an embodiment of the invention;

62 : An example of a brassiere made using a method according to an embodiment of the invention;

63 : An example of a brassiere made using a method according to an embodiment of the invention;

64 : An example of a brassiere made using a method according to an embodiment of the invention;

65 - 73 : Examples of garments made using a method according to an embodiment of the invention;

74 : An example of a ball made using a method according to an embodiment of the invention;

75 : An example of an overhead surface directly connected to damping elements to which outsole elements are attached;

76 : An example of a coordinate system that uses bounding boxes.

5. Detailed description of preferred embodiments

Presently preferred embodiments of the present invention will be explained in the following detailed description regarding sporting goods. In particular, the invention may be particularly useful for the manufacture of shoes described herein. However, as mentioned above, the present invention is not limited to the embodiments described herein. Instead, the present invention may also advantageously be used for the manufacture of other types of sporting goods, for example sportswear such as shirts, brassieres, tights, sports pants, gloves, etc., as well as sports equipment such as balls, ice hockey helmets and protective equipment, sunglasses, spectacles, alpine sports goggles and / or. or bat.

As used herein, a "carrier surface" is any material that is used as a subbing layer for the patches. For example, a carrier surface may be a strip, a tray, a plate, a base material such as a textile, a knitted, woven or nonwoven structure, and / or combinations thereof.

A "patch" referred to herein is a piece of material that can be placed and / or arranged to form a structure. Patches can have any shape, including but not limited to regular shapes such as polygons, such as rectangles, circles, triangles, pentagons, hexagons, etc., as well as irregular shapes, stripes, and / or bands.

The 2a -E show different shapes for patches 10 can be used. As in 2a can be rectangular elements as patches 10a be used. Furthermore, patch can 10b as shown, have rounded corners. The patches 10c can have irregular shapes that are used for design purposes or functional purposes based on patch requirements to have certain characteristics. 2 B shows more regular shapes that as forms 10e -M can be used.

Further shows 2c irregular shapes with knots 12 that can be used and forms with extended elements 14 that as patches 10n -U used. High concentrations of nodes 12 in one area can the strength properties of the patches 10q -T increase. Another extension of the elongated elements, such as the elongated element 14u out 2c , can increase the ductility of the resulting patch in certain areas. Accordingly, the geometries of the nodes 12 and the extended elements 14 Be designed to be the patch 10 impart specific, predetermined properties based on the materials used.

Accordingly, the effect of a patch 10 on the upper of a shoe due to the geometry of the patch 10 in combination with those for the construction of the patch 10 used materials are influenced. As in 2d As illustrated, the use of a plurality of patches in a region may impart certain properties to an area of an upper or shoe that are predetermined by the design or application for which the shoe is used.

The patches 10 can continue to fulfill a design function. As an illustrative example patch 10 be so constructed that he has the in 2e having shown, specific designs. The patches 10 can be used for decorative and / or customization purposes. Accordingly, a person can patch 10 and place them on a shoe according to a user's personal preferences.

2f shows illustrative examples of patches 10 , which are suitable for clothing articles and in particular shoes. As shown, the patches 10 provide a geometry that helps reinforce holes for shoelace elements. For example, patches may be cut (either prior to or during the cutting process) to conform to openings in a base material, such as the eyelets 2f , In this construction, a plurality of patches may be placed on the base material so that holes in the layers are superimposed to form a reinforced lace opening. Using the process described herein, such a construction can be formed using a base material and patches that are placed during the process. In some cases, placement of the patches may provide a finished construction without the need for further downstream processing to make the holes. Other patch types 10 may represent a useful construction for providing stability near a heel on a shoe. Still other patches 10 can provide additional stability and protection in the toe cap area of a shoe.

In the 2a -F shown patches 10 are illustrative examples of patches 10 that can be used. Patch design may be due to patch requirements 10 , Requirements for the article such as a sporting goods, a garment, a brassiere, pants, shirts, tops, shoes or the like and the materials used vary.

The patch materials may include metal (eg, aluminum, titanium, etc.), thermosets (eg, polyepoxides, epoxy resins), thermoplastic polymers such as polyurethane, polypropylene, polystyrene, polyesters (eg, polyethylene terephthalate ("PET")), polyamides, For example, nylon, or other polymers known in the art, thermoplastic elastomers, for example, thermoplastic polyurethane ("TPU"), polyether block amide ("PEBA"), etc., foam, such as expanded foams (for example, ethyl vinyl acetate). Foam, polyurethane foam), particulate foams, for example, expanded particulate foams such as expanded thermoplastic polyurethane ("eTPU"), extended polyether block amide ("ePEBA"), etc. membranes (eg, expanded polytetrafluoroethylene or the like), textile), textile materials, e.g., knit material , Fleece, fabric or similar, hook-and-loop mat erial, fibers such as carbon or glass fibers (eg unidirectional carbon), composites (such as sheet molding composite (eg fiberglass or carbon fibers in resin) with carbon fiber reinforced polymer, carbon fiber reinforced plastic, carbon fiber reinforced thermoplastic), band, for example flocked tape, nonwoven tape, partially transparent tape, dyed tape, printed tape, textured tape, natural fiber such as silk, wool, hair such as camel hair, cashmere, mohair, or the like, cotton, flax, jute, kenaf, ramie, rattan, hemp , Bamboo, sisal, coconut fiber, or the like, leather, suede, rubber, vulcanized rubber, a woven structure, or a combination thereof. The plurality of material patches may be arranged in a manner that a particular area of an article has one or more properties.

In some cases, additives can be added to the material to make patches 10 manufacture. In particular, additives can be added to the patch materials to make the patches 10 to differentiate during the process of deploying patches. For example, optical systems may use a combination of different light sources (eg, ultraviolet light sources, backlight sources), filters (eg, ultraviolet transmission filters), conveyors (e.g., transparent, translucent, or light-transmittable conveyors) and / or cameras (eg, cameras where the ultraviolet and infrared block filters are removed ) to determine the location of a particular patch. In particular, UV additives such as pigments can aid in distinguishing patches that are translucent or have a color similar to the color of other patches, materials, and / or devices such as carriers, grippers, or the like. In addition, other additives can be used to help distinguish between patch materials. For example, additives that are a measurable property of a patch can be used 10 , a support, a substrate, such as a textile or base material, and / or a component, to identify or move these elements.

For example, a backlight can be arranged under a conveyor belt, whereby the position determination for a carrier surface, for example a base material, patches and / or components is facilitated. In particular, you can Backlights can be used in combination with a conveyor belt that is able to transmit light and a camera to identify the position of an upper part.

During the placement can be patches 10 be placed at a predetermined location. In some cases, the placement may be 10 a coupling of the patches 10 at the predetermined location. The coupling of the patches 10 refers to the placement of the patches 10 at a predetermined location in a manner that reduces the movement of that location and / or prevents it in some cases. The coupling can be done by means of chemical or physical mechanisms. For example, the coupling may be the result of friction, adhesion, bonding, magnetic fields (eg, low frequency magnetic fields), static forces (eg, electrostatic charge), hook and loop structures, or the like, and / or combinations thereof.

Materials in patches 10 can be selected based on a physical property of the material. For example, a material for use in a patch may be selected based on properties including, but not limited to, abrasion resistance, traction, strength such as tensile strength, compression strength, fatigue resistance, impact resistance, elasticity, plasticity, conductivity , Breathability, ratio of strength to weight, meltability, deformation, color, transparency, etc.

Patch materials can be used in the form of rolls of different thicknesses and / or widths. For example, patches 10 of polymers having a thickness in a range of 10 microns to 5 mm.

patches 10 can be single-layered. In some embodiments, multilayer patch materials may be used.

patches 10 can be used in a multilayer construction. For example, several patches 10 selected with a thickness of 40 mm applied in areas to give stability to the upper part of a shoe. Single layers of a patch 10 For example, they could be in a thickness range of 0.01 mm to 10 cm.

The 3a - 3t show different illustrative examples of patches 10 according to the invention. 3a shows a single-layer patch 10 , constructed from a base layer 16 , Materials in patches 10 can be used in thicknesses in the range of 0.01 to 5 mm.

patch 10 may be a thermoplastic, such as TPU. Materials used as patches may be single layers or multiple layers of material or different materials. Patching materials can be patch based on the predetermined requirements 10 to be selected. As an illustrative example, a patching material may comprise a TPU layer as well as a fusible layer having different melting temperatures. In some cases, the fusible layer may comprise thermoplastic such as a hot melt layer based on TPY, polyamide, and / or polyester. For example, a TPU having a low melting temperature may be used as the hot melt layer. Some examples may include fusible layers having melting temperatures in the same range as those of the layers in which they are coupled. In some cases, the melting temperature of the fusible layer (s) may range from 20 ° C to about 240 ° C. For example, the melting temperature of the fusible layer (s) may range from about 40 ° C to about 200 ° C. In particular, the melting temperature of the fusible layer (s) may range from about 80 ° C to about 180 ° C.

Patch materials can be provided with integrated hot melt layers to facilitate the construction of the layers, to make the positioning of the patches 10 more accurate, to reduce the movement of the patches 10, and / or to increase the likelihood that the layers will be properly consolidated. For example, the use of a multi-layer patch material having at least one integral fusible layer in patching materials is preferred. In particular, the use of a fusible layer, such as a hot melt layer, with materials that are non-fusible and / or heat-sensitive may help the products to be constructed in a manner that meets the specifications or predetermined properties required of that product.

The 3b - 3t are illustrative examples of patches made up of multiple layers. As in 3b shown, can patch 10 from a base layer 16 and a fusible layer 18 be constructed. The fusible layer 18 can be about the base layer 16 extend. For example, a patch 10 from a base layer 16 be constructed of TPU and a hot melt layer. As an illustrative example, a patch 10 both a TPU and a hot melt layer, wherein each of the layers may have a thickness of about 40 microns. Accordingly, the patch 10 of this construction may have a thickness of about 0.08 mm.

In some designs, the thickness of different layers of a patch 10 may vary. The patches 10 may be constructed to conform to specified thickness specifications, depending on the use of the patch 10 and the materials from which it is made. For example, known properties of a material used in a layer can be used to determine the thickness of that layer as well as to determine the other types of material with which it is to be paired to create a patch 10 with the predetermined necessary properties.

In some cases, as in 3c shown, the fusible layer 18 is not continuous, in the form of the elements 20 , For example, the fusible layer 18 may consist of various geometries, for example, one or more points, rectangles, a mesh, amorphous shapes (eg, a spider web), lines, or fixed geometries specific to use or design. As in 3c As shown, the fusible layer 18 may be a series of dots of the hot melt layer. In some cases, the fusible layer may be permeable to air. For example, as in 3d shown, the fusible layer 18 a plurality of elements 20 include, between a support surface 22 and a membrane are arranged. The fusible layer 18 may be arranged to permit air passage through the patch 10.

patch 10 can on the support surface 22 be arranged and the base layer 16 and the fusible layer 18 as in 3e illustrated. In an illustrative example, shown in 3f , Patches 10 can be a fusible layer 18 and textile 26 include on the support surface 22 are arranged. The base layer 16 may be a TPU that is responsible for changing the physical properties of the patch 10 can be used, for example, to provide rigidity, retention properties, providing and maintaining a shape of patch 10, reducing water absorbency, or the like. The textile 26 can be selected for a variety of reasons, including but not limited to the design, physical properties such as grip, feel, conductivity, breathability, and / or design.

Further illustrative examples of multi-layer patches 10 are in the 3g and 3h shown. As in 3g shown, can be a patch 10 include: a fusible layer 18 , a base layer 16 (For example, TPU) and a textile 26 , arranged on the support surface 22 , An alternative construction, shown in FIG 3h , comprises a fusible layer 18 , a base layer 16 (For example, TPU), a second fusible layer 18 and a textile 26 , arranged on the support surface 22 , The carrier surface may be a textile or a base material, for example a knit fabric, depending on the requirements of the cover layer.

Some patches 10 may also include materials disposed within materials. As in 3i shown, the thermoset material 28 between two layers of the base layer 16 to be ordered. A thermoset used in this way can fix the patch 10 strengthen. Thermoset materials may include, but are not limited to, polyurethanes such as polyurethane polymers, silicone elastomers, rubber, vulcanized rubber, melamine resins, diallyl phthalates ("DPA"), epoxy resins, polyimides, cyanate esters or polycyanates, polyester resins, vinyl Ester resins, phenols, etc.

As an illustrative example can be a patch, as in 3y is shown, made of TPU and a fusible layer 18 and thermoset material 28 constructed base layers 16 include, on a textile as a carrier surface 22 are arranged.

In some cases, metals such as steel may be disposed on a textile support surface between layers of TPU.

3k shows another illustrative example and shows an insulation material 34 standing on a support surface 22 is arranged. The insulation material 34 comes with a fusible layer and a base layer 16 fixed. In some cases, the insulation material may provide a spring and / or shock protection for the patch.

As in 3l Another illustrative example illustrates the use of a foam material 36 that between two base layers of a thermoplastic material 16 is arranged and on a support surface 22 is arranged. Foam may be used to impart advantageous spring properties to predetermined areas of the shoe. Foam materials may include, but are not limited to, expanded foam materials, expanded particulate foams such as expanded polyurethane thermoplastic particle foams (ie "eTPU" particulate foams), polyurethane, ethylene vinyl acetate foam ("EVA"), cork, etc.

Another illustrative example is in 3m shown that a multi-layer patch 10 illustrated on a support surface including a fusible layer 18 , a nonwoven layer 38 , a topcoat 52 and a printed layer 54 is arranged. As shown, the topcoat 52 a polyurethane coating, and the printed layer 54 can be formed by digital printing.

3n shows a patch 10, arranged on a carrier surface 22 with a meltable layer 18 , Textile 26 and a rubber layer 56 , As shown, the gum can be continuous over the textile 26 extend. In some alternative illustrative examples, the rubber may 56 in a non-continuous way on the textile 26 to be placed.

In some cases, the layers may be activated prior to assembly of the patches 10. For example, shows 3o a textile 26 and a carrier surface 22 passing over a molten zone 58 are coupled. The molten zone 58 can by heating the textile 26 be formed before the textile 26 on the support surface 22 is placed. For example, the textile 26 be heated by infrared welding ("IR") before it reaches the carrier surface 22 is placed.

As in 3p Shown are the fusible layers 18 used to fix layers together. 3o shows a fusible layer 18 that is between a base winner 22 and an injection molded component 60 is arranged.

In some cases, a multi-layered patch construction may have layers with different melting temperatures. For example, a patch 10 on a support surface with a low melting point thermoplastic polymer, followed by a textile and a cover layer of TPU. The low melting point thermoplastic polymer may be a low melting temperature TPU. In some cases, the fusible layer may be selected for washability so that its melting point is above 40 ° C.

Another illustrative example of a patch material may include multiple layers of a hot melt material surrounding a base layer such as TPU. It may be desirable to use a TPU that is designed to be ductile and has good recovery properties, as well as an inner and outer layer of hot melt material. In some cases, such a construction may include another outer textile layer.

Further illustrative examples of patches 10 , which are arranged on midsoles, are in the 3q -T shown. 3q shows an outsole element 62 that's right on a midsole 4 is attached. For example, a TPU outsole element 62 be directly connected to a midsole, which has been made of an expanded particle foam, such as an expanded thermoplastic polyurethane particle foam.

As in the illustrative example of the 3r -T shown, the fusible layers 18 For example, hot melt layers are used as an intermediate layer to the outsole elements 62 with the midsole 4 connect to. For example, different materials can be interconnected by means of fusible layers 18 For example, spring materials such as expanded foams, for example, ethyl vinyl acetate ("EVA") foam, polyurethane ("PU") foam, etc., expanded foams, rubber, textiles, polymers, synthetics, and combinations thereof. For example, the hot melt layer 18 used to make the outsole elements 62 with a midsole 4 especially when it comes to materials that do not bond well.

3r shows the use of the fusible layer 18 that can be used to make the outsole elements 62 with a midsole 4 to pair. As an illustrative example, a hot melt layer 18 used to be an outsole element 62 made of rubber with a midsole, which consists of expanded foam, such as ethyl vinyl acetate, or a particle foam, such as expanded thermoplastic polyurethane particle foam.

In some cases, rubber elements or patches 10 be coupled with foam materials by means of a fusible layer. As an illustrative example, a patch 10 in the form of a rubber outsole element, are coupled to a eTPU midsole by means of a hot melt layer. Furthermore, fusible layers can be used to couple other materials to rubber. For example, a hot melt layer can be used to make rubber patches 10 to couple with the textile of a cover layer. In some cases, textile materials can act as an outer layer on a patch 10 be used. Alternatively, rubber patches may be vulcanized directly onto a portion of an upper, midsole and / or outsole.

3s shows the use of a fusible layer 18 for coupling a textile 26 With a midsole 4 , For example, a knitted or woven patch 26 by means of a hot melt layer 18 with a midsole 4 made of an expanded particle foam, such as an expanded thermoplastic polyurethane particle foam.

3t shows the use of a fusible layer 18 for coupling an injection molded component 60 to a midsole 4 , For example, an injection molded element 60 by means of a hot melt layer 18 with a midsole 4 made of an expanded particle foam, such as an expanded thermoplastic polyurethane particle foam.

Depending on the properties of the material being joined, some designs may not require hot melt layers. For example, a TPU outsole member may be directly coupled to a eTPU midsole member.

For example, a textile material on the outside can bring about better optical properties, in particular digitally printed textiles, for example printed bands, such as those used in seatbelts, printed elastic bands, etc.

Furthermore, patches can 10 be placed so that they have transition zones with a controlled extensibility / stiffness.

patches 10 and / or patch materials may be non-isotropic. In some cases, it may be beneficial if patches 10 and / or patch materials have properties that vary along an axis of the patch 10 and / or patch material. For example, the patches 10 be constructed so that the behavior of the patch 10 varies along an axis.

The provision of a pattern on patches 10 Can be used to set properties of the patch 10 such as extensibility, stiffness, thickness, grip, etc. Patterns can be applied to the patch as in the 4 . 5 . 41 represented, engraved. Such patterns may differ in depth to vary the physical properties of the patch material across the patch. For example, an engraved patch 10 may be applied at the transition from forefoot to midfoot to allow for extension.

In some cases, as in 4 represented, lamellas 64 on a patch 10 be arranged. The slats 64 can the stretchability of the patch 10 influence, in particular by the fact that additional elasticity is made possible perpendicular to the slats. Furthermore, the slats 64 or another design engraved or cut into the patch, in some cases the friction between the patch 10 and an opposite surface. For example, an engraved patch 10 on a football boot have better grip when in contact with a football than a patch 10 without structures on its surface.

In some cases, a engraving pattern 66 on patches 10 be provided to control the stiffness or flexibility, for example near the toe area, as in 5 shown. As shown, the slats are 62 on the lateral side of the patch, which is applied over the toe cap, more clearly highlighted. This can be the flexibility of the patch 10 and the upper on the lateral side.

Furthermore, other regions, such as the heel area, can engrave on patches 10 partially, to control rigidity. In particular, a heel area may be the application of patches 10 benefit in a way that allows the patch configuration to affect the extensibility of the heel area. For example, the patches 10 be arranged to allow or control stretch in predetermined areas of the heel. In particular, a heel area may have a stretchable area with few patches 10 or visible patches 10 near the Achilles tendon to allow stretchability. In contrast, on both sides of the Achilles tendon patches 10 used to control extensibility and to provide rigidity.

Furthermore, patches can 10 constructed on or near the flap of the shoe with lamellae or an engraving pattern so that the extensibility is controlled from toe to heel.

In some cases, additional materials may be placed on top of patches to give properties to the patch and / or article. For example, elements can be printed on the patch. Alternatively, small rubber patches can be vulcanized onto parts of an upper or onto patches.

In some embodiments, a support surface may include parts that have been removed. In some embodiments, patches 10 be added to reinforce parts of the support surface, for example a base material.

In some cases, patches can 10 be applied and then later brought to the bar in 3D form.

6 shows an embodiment of a production method according to the invention. Using the procedure, patches 10 and / or components 10 for the substantially automatic production of an upper shoe, ball case / ball scaffold, shoe sole, or the like.

As in 6 You can see patches 10 by means of a cutting device 7 from a coil 5 or a strip of material (not shown) cut and in step 100 placed on a transport device. For example, the transport device 12 a band, such as a conveyor, a band of tissue, for example, a band of tissue used in an upper shoe, a tray, a plate, etc. Materials that may be used in the transport device include, but are not limited to, flexible materials such as textiles or solid materials such as metal, glass, ceramics, or the like.

In some cases, the transport devices may be constructed of low thermal conductivity materials. In some cases, it may be useful for the materials used as transport devices on which consolidation takes place, if they have a thermal conductivity of less than 25 watts per meter per Kelvin (W · m ^-1 · K ^-1 ). For example, in some embodiments, it may be desirable to use a material having a thermal conductivity of about 1 watt per meter per Kelvin (W · m ^-1 · K ^-1 ). For example, when consolidating a three-dimensional upper, a thermoplastic last may be used.

In some cases, the transport device may include release elements that are capable of releasing the patches from the transport device. This can reduce the force required to move the patches. Release elements may include coatings on the transport device, ejector pins disposed on the transport device, or other release elements known in the art. As an illustrative example, ejection pins may be disposed within the transport device. The ejector pins can be activated prior to gripping the patches to allow the patches to be picked up by the grippers using less force.

It is also conceivable that several material coils 5 be deployed to simultaneously different types of patches 10 provide. The patches will then step by step individually 200 by a gripping device 15 added, and a glue component of the patch 10 is activated. The adhesive component can be activated using energy. Energy required for the activation of the adhesive component and / or the patch 10 may include, but are not limited to, electromagnetic energy such as infrared, radio frequency, ultraviolet energy, microwave, thermal and acoustic energy such as ultrasonic energy, etc., as well as combinations thereof.

For example, in step 300 Heat through an infrared "IR" lamp 17 or a similar source of energy 17 provided. Activation of the adhesive component of the patch 10 Can be controlled so that only a part of the adhesive component is activated to the patch 10 to couple to the carrier surface.

A patch 10 or a component 10 with a glue component may be placed adjacent to an energy source and / or energy from a source may be controlled so that only a portion of the glue component is activated. As an illustrative example, the energy of an IR lamp can be controlled so that the adhesive component of the patch 10 is selectively heated to activate only a portion of the adhesive component.

In one particular example, the energy from the IR lamp may be controlled to activate only the portion of the adhesive component that is the centerline of the patch 10 equivalent. In some cases, an area may be the midline of the patch 10 and about 2.5 mm on each side of the centerline, in such a manner that the width of the activated area is about 5.0 mm. The activation of the patch can also take place over a width of 20 mm. For example, in one illustrative example, the activation area may extend beyond 10 mm in either direction on each side of the centerline.

Based on the geometry, the selected materials, and / or the functionality of the patch and / or the component, the activated area may vary in position, width, length, and / or shape. In particular, some patches and / or components may have an activated area corresponding to the entire area of the patch. In alternative examples, the activated region may be part of the patch and / or the component. In some cases, the activated area of the patch and / or component may be less than about fifty percent of the surface area available for connection. In some cases, the activated areas may correspond to a range of less than about 25 percent of the surface area of the patch and / or the components available for connection. In one particular example, the activated area may be less than 10% of the surface area of the patch and / or the component available for bonding to the substrate surface.

For example, the activated area may have a width of less than 25 mm along the length of the patch. The width of the activated area may be less than about 15 mm. In particular, the activated area may have a width of less than about 10 mm. In some cases, the activated area of the patch may have a width of less than about 5 mm.

The activation range of the adhesive component of the patch can be controlled based on the geometry of the patch.

In some cases, the activation region may correspond to the first contact point with a support surface for the component, and in particular a patch. For example, an activation area may correspond to the centerline and / or the center of a patch, which is then used as the first point of contact with the substrate surface.

In some cases, the arrangement of the patches 10 Be controlled in addition to a source of energy so that only an outer layer of the adhesive component is activated to the patch 10 to couple to the carrier surface.

The patch 10 can then be on a two-dimensional or three-dimensional support surface 20 to be placed. In step 400a is a two-dimensional surface 20 in the form of a flat surface (for example a worktable), a flat base material (for example a knitted material or a midsole). step 400b represents a three-dimensional support surface 20 such as a 3D shape (for example, a last). The process of placing the patches may be as desired for a plurality of patches 10 be repeated.

After the patches 10 on the carrier surface 20 placed, finds an optional consolidation in the steps 500a and 500b by the use of a flexible membrane, such as a stretchable silicone skin. The flexible membrane 25 can be shaped to suit the profile of the support surface 20 follows, for example, the upper shoe. For example, in one on a last 20 formed 3D upper shoe, the flexible membrane 25 essentially the contour of the last 20 consequences. It should be emphasized that the process according to the invention does not require the use of a rigid mold, a rigid negative mold component or a rigid upper part.

In some cases, a rigid top can be used to attach patches to flat or 2D articles, such as tops, pants, shorts, shirts, brassieres, and / or sweatshirts. As an illustrative example, a rigid plate 68 used to the patches 10 on an upper during the consolidation process, as in 7 shown to provide heat and pressure.

The 8a -C show three options for the consolidation step 500a / 100b , In 8a becomes a substantially planar silicone skin 25 used on a frame as a flexible membrane. The flexible membrane 25 gets on top of a plurality of pre-ordered patches 10 placed, in turn, on top of an upper 20 are arranged, which forms a two-dimensional support surface. In 8b becomes a preformed silicone skin 25 used as described above and on a patched upper 20 placed, so an upper shoe with pre-ordered patches 10 ,

8c shows another possibility, more specifically the use of a heated oil bubble 25 that on the patches 10 is placed to act in a manner similar to the flexible membrane.

The 8a -C also show optional heating of the consolidated patches 10 and the flexible membrane 25 by means of a hot table 22 on which the components are arranged. The use of a hot melt layer on the patches 10 One possibility in this scenario is that it allows fast turnaround times as well as ease of use without overflow, as well as a homogeneous hot melt distribution. Other heat sources are also possible. To further enhance consolidation, a vacuum can be made by passing air from the consolidated material through the table 22 is withdrawn, as shown by the arrows in the 8a -B from the table 22 pointing downwards.

As in 9 an illustrative example of a patching process is shown here. As in 9 Obviously, there will be patches 10 by means of a cutting device (not shown) from a coil 5 or a strip of material (not shown) cut and in step 400 placed on a carrier device. For example, the carrier surface 22 a band of fabric, for example a band of fabric used in an upper shoe, an upper shoe, a textile element, a midsole, etc.

It is also conceivable that several material coils 5 , several strips of materials and / or patches 10 be deployed to simultaneously different types of patches 10 provide. The patches 10 will then step by step individually 200 by a gripping device 15 added, and a glue component of the patch 10 will be in step 300 activated. The adhesive component can be activated using energy. Energy required for the activation of the adhesive component and / or the patch 10 may be used to include, but are not limited to, electromagnetic energy such as infrared, radio frequency, ultraviolet, microwave, thermal and acoustic energy such as ultrasonic energy, etc., as well as combinations thereof.

For example, heat is transmitted through an infrared ("IR") lamp 17 or one in 9 shown step 300 provided. The adhesive component can also be provided separately. The patch 10 can then onto a two-dimensional support surface 22 to be placed. In step 400 is a two-dimensional surface 22 in the form of a flat surface (e.g., a worktable), of a flat base material (eg, a knit material or a midsole).

After the patches 10 on the carrier surface 22 are placed in place 500 an optional consolidation through the use of a flexible membrane 25 For example, a stretchable silicone skin instead. As in 9 shown, the flexible membrane [member] 25 with the rigid member 68 be coupled. The rigid link 68 can be used to move the flexible membrane [member] 25 so that consolidation can take place.

In some cases, the application of pressure and / or heat during consolidation may be both in terms of intensity and time over which the heat and / or pressure is applied based on the materials selected, the number of patches, the thickness of the materials which position of the patches on the article and / or use of the article are controlled.

Consolidation may take place at a temperature in a range of 40 ° C to 240 ° C. Furthermore, some constructions may be performed at temperatures in the range of 55 ° C to 200 ° C. Furthermore, there may be constructions in which the consolidation is carried out at temperatures in the range of 80 ° C to 180 ° C. The temperatures described here may be the initial membrane temperature.

The pressure during consolidation can be controlled so that the pressure is in the range of 1 bar to 10 bar. In some cases, the pressure can be controlled during consolidation in a range between 1.1 bar and 4 bar. Furthermore, the pressure during the consolidation can be controlled in a range between 1.5 bar and 2 bar. For example, using very thin patches made of, for example, tape, less time and pressure may be used, for example, 180 ° C at 1.5-2 bars over a period of 60-90 seconds.

A number of consolidated layers may further affect the time required for the connection. For example, in one illustrative example, four layers of patches were bonded using a membrane having an initial temperature of about 180 ° C. Furthermore, in another example, the bonding of five layers of patches was completed at 180 ° C after about 90 seconds of consolidation.

Patching of materials on a support surface or article may further involve other methods of coupling the patches to the surface of interest, be it the support surface, another patch, and / or another component. In 10 FIG. 3 is an illustrative example of a portion of a patching process in which a substrate surface is shown 22 selected and on a transport device 30 can be placed. Patch materials may be provided on a spool as described above and cut, pre-cut or provided on a flat belt and cut out. As shown, the carrier surface - in this case a base material - and / or the transport device 30 by means of a loading device 70 be charged electrostatically. The patches 10 can be applied to the base material 72 to be placed. Due to the electrostatic charge of the base material 72 can the patch 10 to the base material 72 Be "coupled". This electrostatic coupling allows the base material and patches to be moved without changing the position of the patches on the base material. In some cases, the patch construction may be consolidated using the methods described herein.

In some cases, the electrostatic charge is output using a static charging system that includes a high voltage generator that provides the required voltage to effect a static charge, such as an electrode. Charging electrodes may be such that configurations and / or shapes can be optimized for a particular application. As in 10 can represent the electrode 70 over or opposite a grounded transport device 30 be placed. After application of the electrostatic field, the base material is temporarily attached to or bonded to the grounded surface of the carrier. Furthermore, additional pieces can be placed on the base material and fixed by means of the electrostatic charge. As in 10 presented, may be a patch 10 on the base material 72 placed and thus coupled with the base material. Accordingly, the patch does not slip and does not change its position. In some cases, antistatic foam material may be used which allows complete contact with the base material and helps to disperse the electrostatic charge.

11 shows another illustrative example of the patching of materials using electrostatic forces. In particular, a carrier surface becomes 22 on the transport device 30 placed. As shown, a carrier surface 22 as base material 72 be used. Using a charging device containing an electrode 74 and an artificial grounding 76 (For example, a virtual ground, an antistatic rod), the carrier surface 22 and the transport device 30 loaded. This allows the arrangement and coupling of patches 10 pointing to the support surface 22 be applied. In some cases, multiple patches can be placed and coupled using electrostatic adhesion. The antistatic rod acts as a grounding in this case. The final attachment may be done using the consolidation process described herein.

In some cases it may be necessary to eject the last article before, during or after the consolidation process.

12 shows gripper 15 that the patches 10 retrieve. In this case, the carrier surface 22 a material that is both as a base material 72 as well as a transport device acts. Grippers can be used to make patches 10 select and position. Furthermore, patches can 10 on the base material 72 be placed while from the electrodes 74 . 74 a charge is issued. Accordingly, patches may be placed on both an exterior and an interior surface, for example a base material 72 an upper material.

The use of electrostatic adhesion to position and couple the patches to the base material and / or the substrate surface can reduce the throughput times for the article assembly by eliminating one step in the process. Furthermore, in some cases this provides flexibility in placing patches on both surfaces of an upper.

Patch processing of articles may involve the combination of one or more of the methods and methods described herein for positioning and coupling patches to a substrate surface or base material. In some cases, it may be desirable to use patch processes that use electrostatic charge with patch processes that use activated patches. For example, a base material may be electrostatically charged and the patches are placed by electrostatic charge. Additional patches can be placed using activation of a patch adhesive component. Such a configuration may be helpful, for example, if the base material is a textile belt that functions both as a carrier surface and as a transport device. Such a configuration may allow the placement and coupling of patches on both sides of the base material. Furthermore, such a configuration may be of interest when some materials and / or constructions used are not suitable for coupling to the support surface or other surface by means of electrostatic charge.

After the arrangement of the patches 10 on a support, for example a base material or a 3D form, the patches can 10 connected or attached using a consolidation process.

After the patches 10 on the base material, an optional consolidation step takes place through the use of a flexible membrane, such as a stretchable silicone skin. As in 13 shown, the flexible membrane [member] 25 with the rigid member 78 be coupled. The rigid link 78 can be used to move the flexible membrane [member] 25 so that consolidation can take place. The zone 80 can be pressurized so that the flexible membrane [member] essentially replicates the shape of the material for consolidation. Furthermore, the pressure in the zone 80 be controlled so that a predetermined pressure during the consolidation process over a predetermined period of time based on the selected materials is added to the patches. In some cases, heat can be applied to the patches using the flexible membrane [member] 25 10 be applied. In other cases, the rigid member 78 Provide heat to the patches to consolidate them. Furthermore, in some cases, heat may be provided through and / or from the support surface.

Patch materials may be provided on a spool as described above and cut, pre-cut or provided on a flat belt and cut out.

14 shows a vivid example of another consolidation process 500 that can be used to consolidate patches. In particular, a plurality of flexible membranes [members] 25a, 25b may be used. The flexible membrane [member] 25b can be arranged to match the patches 10 in contact. In some cases, the flexible membrane [member] 25b may be the patches 10 Texture when applied using heat and / or pressure. The consolidation structure 82 may be constructed such that the flexible membrane [member] 25b is interchangeable. This would allow different textured pattern configurations on different flexible membranes [members] 25b that can be interchanged. The flexible membrane [member] 25a can apply heat and / or pressure to the flexible membrane [member] 25b , the patches 10 and the carrier surface 22 exercise, which is shown as a textile. Alternatively, using the flexible membrane [member] 25a Pressure over the pressure zone 89 be exercised, and heat can be from wearer 17 to be provided.

15 shows a patch process involving the cutting, placement and consolidation of patches or elements on a substrate surface 22 , in particular on an upper material, which is arranged on a 3D form. In 15 is a shoe last 84 represented as the 3D shape. The process for the steps 100 , 200 and 300 is essentially the same as the 2D process, as in 6 shown. In some cases, grippers can be adapted to position the materials on a 3D mold. As an illustrative example, a gripper 15 used for positioning materials on a 3D mold, such as a shoe, having a foam member having a greater thickness such that the foam member contacts the shoe last 84 can be deformed without affecting other parts of the gripper 15 the upper shoe 102 and / or the patches 10 can touch.

In the illustrative example explained above, the support surface 22 in particular a three-dimensional support surface, comprise a work mold, for example a last, a base material resting on a working mold or a combination thereof.

As shown, the consolidation step 500 the positioning of a carrier surface 22 within the consolidation structure.

As in 16 shown, the consolidation structure includes the flexible membrane [member] 25. The zone 80 can be pressurized to pressurize the flexible membrane [member] 25. The flexible membrane [member] 25 may consist of many parts or, in some cases, a single piece. The pressure within the zone 80 can be controlled so that a set pressure on patches 10 and / or the carrier surface is applied through the flexible membrane [member] 25. Heat can be generated by the application of heat in the zone 80 on the patches 10 and the carrier surface 22 be applied. The application of heat and / or pressure over a period of time may be controlled so that the temperature, pressure and time values correspond to specified values for materials and / or constructions. In alternative embodiments, heat may be applied to the patches and / or supports using the flexible membrane. Any method of applying energy or heat to the patches can be used to consolidate the patches. For example, heat and / or energy may be provided for consolidation by electromagnetic energy, such as infrared energy, thermal energy, ultrasound, convection, and combinations thereof.

The zone 80 can be pressurized so that the flexible membrane [member] essentially forms the shape of the material for consolidation. Furthermore, the pressure in the zone 80 be controlled so that a specified pressure during the consolidation process over a fixed period of time based on the selected materials on the patches is pitched. In some cases, heat may be applied to the patches 10 using the flexible membrane [member]. In other cases, part of the consolidation structure can provide heat for the patches to consolidate them. Furthermore, in some cases, heat may be provided through and / or from the support surface. For example, heat may be applied by means of a heated last to at least a portion of the plurality of patches.

Furthermore, a flexible membrane can be provided as a band on a conveyor belt. For example, the flexible membrane can be rotated between the consolidation processes. So any consolidation process can start with a "new" part of the flexible membrane. In some cases, a flexible membrane on a conveyor belt may be treated differently at different locations on the belt to allow for various surface treatments during the consolidation process.

Consolidation using any of the methods described herein can be a multi-step process. As an illustrative example, a first consolidation process may take place at a temperature of 100 ° C at a pressure of 2 bar for a period of sixty seconds. The second consolidation process may take place at the same pressure of 2 bar and over a period of sixty seconds, but at a higher temperature, for example at a temperature of about 180 ° C. Consolidation conditions, including time, pressure and temperature, as well as a series of consolidation steps, depend on the designs and materials used in the articles.

17 shows a procedure for cutting patches from materials. In particular, a process for the removal of excess material after the material becomes patches 10 was cut. The material is visible first from the first spool 5 unrolled and using, for example, a laser 7 cut into patches, and the excess material 86 is from the conveyor belt 12 automatically removed. The positioning device 27 is a moving part that exerts pressure on the material while it is being cut. After cutting, the positioning device 27 to move, with surplus material 86 from the patches 10 can be disconnected and removed. In some cases, the excess material may be wound onto another spool (not shown) for further processing and / or recycling purposes.

In a further aspect of the invention, the step of providing a plurality of components, the steps of providing material from a spool, a belt, a tray and / or a stack to a transport device, cutting the plurality of components of the material under Use of a cutting device and the removal of excess material from the transport device take place automatically. For example, materials may be processed by providing the material using a first coil, cutting out the majority of the components using a cutting device, and preferably removing the excess material using a second coil. Such a "reel-to-reel" process, which results in the automatic removal of excess material after cutting, may be fully or partially automatic, thus providing significant efficiency improvements. A coil process with embodiments according to the invention may further comprise a carrier layer to avoid adhesion between the layers, which can be automatically removed.

As in figure 18 shown, can be a patch 10 be cut using a multi-step process. For example, a patch 10 partly from the material 88 Being processed will be cut. Excess material 90 can then be removed. Additional cuts can be made to the patch 10 from the material 88 to build. Excess material 90 can be removed. In some cases, the excess material may be removed using a conveyor system, such as a coil process. In some alternative embodiments, patches may be removed from the material and the excess material may remain on the transport device after cutting, if any.

In some cases, the cutting device can be used to make patches or engraving patterns (eg, slats, decorative designs, logos, trade marks) from patches. For example, the in 2f shown openings are made during the cutting process using a laser source to remove material. Places of patches or components can be determined using a localization system before they are changed. Such a location system may be an optical system, a system that determines position based on pressure, light transmittance, as well as any other positioning system known in the art.

19 shows a preferred gripping device 15 for use in embodiments according to the invention. The gripping device 15 includes a plurality of individual grippers 15a that can be modularly arranged. In this way it is possible to use all conceivable types of patches 10 irrespective of their composition, material and shape, easy and reliable to process. In the embodiment of 19 So-called "Coanda grippers" are used in the prior art. Coanda grippers use the principle of the Coanda effect; this refers to the phenomenon according to which a jet flux abuts an adjacent surface and continues to abut it, even if the surface moves away from the original beam direction by curvature. In a free environment, a liquid jet mixes with its environment and entrains it as it flows out of a tap. By attaching each gripper 15a on an adapter plate 15b, it is possible to have a plurality of grippers 15a to be flexibly arranged so as to form a desired gripping device. Preferably, each gripper 15a is further provided with a flexible foam member 15c equipped to allow the device the patches 10 record and place. 19 also shows a silicone membrane 15d under the flexible foam element, which can be used to protect the foam from the heat. Furthermore, the silicone membrane can be perforated to distribute the air flow.

In some cases, the flexible foam member of the gripping device may provide a surface capable of transporting patches as well as parts made of different materials. For example, a gripping device may be provided with a flexible foam element capable of receiving parts and / or patches having an irregular shape and / or materials with different breathability.

The flexible foam element may be molded for a particular use. Configurations of the flexible foam member may vary depending on the geometry and / or material of the component, carrier surface area, type of adhesive, etc. For example, the foam member may close to and / or near the point where the foam member contacts a component (eg, a patch, structural member, outsole member, midsole member, a closure mechanism, an electrical component, a sensor, a mechanical component, etc.) the point at which the component first touches the carrier surface will be thicker. For example, the foam member may be a substantially semicircular member constructed such that the apex of the semicircular foam member corresponds to the point of contact for the component or patch so that when the patch is placed, the first contact point between the patch and the support surface corresponds to a centerline or a midpoint of the patch.

Depending on the materials to be arranged, a rigid plate may be suitably used on the gripping device in some cases.

Grippers can also be used on different properties for different parts of the process. Materials to be moved as well as desired application pressures, provision of energy (eg, heat), desired positioning accuracy, etc., may each be taken into account as factors in selecting a gripper for the delivery of a material, such as a patch or component, at its position on an article become.

Grippers may include, but are not limited to, grippers that use friction, such as gripper grippers, vacuum grippers (eg, vacuum grippers, Bernoulli grippers, Coanda grippers, or the like) that use electrostatic forces, such as electrogrip grippers that use adhesion, such as grippers such as grippers those using adhesive film, cryogenic grippers using mechanical fit, such as needle grippers and / or combinations thereof.

As an illustrative example, an electro-adhesion gripper can also be used. In particular, electro-adhesion grippers can be used on 2D elements. The construction of a modified electrostatic gripper corresponding to a shape of a 3D support surface may allow the use of such a gripper to place the patches on 3D articles, especially shoes.

23a Figure 4 shows an illustrative example of a device capable of performing the patch placement methods described above. 23b Fig. 12 is a perspective view showing the various components of a so-called "3D cell" because it uses a three-dimensional support surface. As can be seen, the device comprises a six-axis robot 36 with which a last 20 connected to a pre-arranged base material. Material is from two coils 5 unwound and using a Laer cutter 7 cut into patches (see the in the reception area 34 in 9b designated patches). During the receiving part of the process can be an optical system 30 used to create components, patches or the like, as in 23a shown to identify.

Alternatively, parts, such as patches or components, during the recording process and / or patch process using optical system, laser scanners, laser-optic scanning systems, mechanical gauges, coordinate systems generated on the basis of design files, may be any in the art The technique of known methods and in combination with software such as computer-aided design software ("CAD") and / or combinations thereof are identified and located.

The device further comprises a four-axis robot 32 , which is able to pick up and position parts. Accordingly, the robot takes 32 individual parts 10 from the reception area 34 on, activates these using an IR lamp assembly 17 and place them on the last 20 ,

For the placement of the individual patches 10 For example, a coordinate system may be used based on the face pattern generated based on the design file and as described herein 76 is described. The coordinate system is set for each layer of the construction. For example, for the base material in the Trap of an upper and all patch materials. A zero point XX may correspond to a center of the bounding box that may define the gripping point for the material. In some cases, the X-axis may be defined as the tape feed direction. In some cases, this robot may continue to be equipped with an optical system capable of positioning parts, especially patches or components.

Alternatively, any robot known in the art or a combination of multiple robots may be used to obtain the same results. For example, a seven-axis robot can be used. In other scenarios, multiple robots with fewer degrees of freedom may be used in combination to obtain similar results.

Referring again to 23a An exemplary embodiment of an apparatus for producing an embodiment of a method according to the invention will be described in detail. As can be seen, the production cell, which has already been explained above, is an embodiment which is arranged within an at least partially transparent container, so that the operation of the device can be viewed from the outside. In the present embodiment, the walls of the container may comprise glass or Plexiglas or other transparent materials.

23c FIG. 10 is a plan view of an apparatus performing an embodiment of a patch placement process on a two-dimensional support surface. FIG. As can be seen, similar to the device described above, the device also comprises 23c Do the washing up 5 Material, a laser cutter 7 , a reception area 34 and a four-axis robot 32 , Instead of the last 20 places the device out 23c the patches 10 on a flat carrier surface, more precisely a base textile 20 , As shown, the flexible membrane 25 mounted on a frame, which, as described above, the consolidation of the components is used.

23d FIG. 10 is a top view of another device performing an embodiment of a patch placement process on a three-dimensional support surface. FIG. Again, the device comprises coils 5 Material, a laser cutter 7 , a reception area 34 and a four-axis robot 32 , Furthermore, the device comprises a six-axis robot 36 who is capable of making a last 20 from a magazine 38 which is then used as a carrier surface. Furthermore, a preformed, flexible membrane 25 shown as described above, as well as a human operator 40 ,

Additional elements may be added to the "part with patches" before and / or after consolidation. Such elements may include on-site components produced on the production line and / or prefabricated components. The elements may include components formed by molding (eg, heel caps, cages, support structures), outsole components (eg, a bolt, a tab, outsole members), eyelet reinforcements, fastener mechanisms (e.g., laces, lace structures), structural members (e.g., tubes, straps), and / or other components that are useful for the "patch part".

20 shows an embodiment of an automatic, computer-aided manufacturing process according to the invention. First, a design specification of the sports item to be produced is revealed in step 600 provided in the form of a design file, such as a CAD file, especially in DXF, ASCII, or any other format known in the art.

A design file is created for each article model, such as a shoe model. Design files are generally created by the designer of a shoe. The design file outlines all possible combinations for a particular shoe design. For example, the design file may include shoe specifications such as shoe size, constructions, patch sizes, component sizes, coordinates for positioning parts such as patches, components, etc., or the like, and combinations thereof.

A design file is preferably a multi-layered file capable of defining many or all of the elements of the article to be constructed. As an illustrative example shows 24 a DXF file of a shoe. Each layer in the file defines the shoe with more specificity. The shoe may be defined as a model name, article number or the like. The size may be defined according to the dimensions of the sizes used in the prior art. The page may refer to which shoe is affected, the left or the right.

25 shows a more detailed view of the layers in the DXF file. Each shoe is defined across different levels or components, such as a base material, patch 1, patch 2, etc. Each component that is part of the shoe may have a coordinate system (as in 76 shown) as well as a bounding box, a shape and / or a logo or the like (as in 26 shown).

The design specification included in the design file preferably includes one component per design layer and a layer structure related to the chronological order of assembly. A software program then translates in step 700 the CAD file into a production plan. In 20 For example, the production plan is represented by the numbered, individual shoe components that are to be assembled (that is, the outsole, the upper, a first type of patch 10, and a second type of patch 10). In particular, the order of assembly can be determined automatically by the software. The production plan can also be in step 800 can be used to train the robot (s), the optical systems, etc. as explained below.

For example, a designer may design a shoe design using two-dimensional and / or three-dimensional software such as Adobe Illustrator, Maya, Modo, Rhino, CAD, or other software known in the art.

In some cases, a design file can be converted to a geometry file using conversion software. The conversion software can determine the length of the patches and the orientation to ensure proper positioning. The conversion software may support the use of optical systems and / or positioning systems. For example, optical software such as Halcon can be used as conversion software. Software can be used to convert data from the DXF file into a usable format. For example, data stored in the DXF file can be used to identify patterns [sic: create] and emulate them on the article to be patched. Geometry files may define the shoe in terms of construction using patches and arrays.

An illustrative example of an algorithm for making an article is in 27 shown, in particular for the production of a shoe using 2D placement of materials. The design file 92 may be a DXF file that includes the specifications for a shoe model for multiple shoe sizes. The geometry file comes with the conversion software 96 into a geometry file 94 converted. The information from the geometry file, the material database 98 and the job file 146 become a controller 148 (for example, a device controller). The control 148 controls various systems required for the manufacture of the article. For example, material procurement 150 (for example, where the material is stored), material supply 152 (For example, unwinding materials, delivering materials from a storage location to where they are needed), processing 154 (for example, cutting), tracking 156 (eg optical systems), positioning systems 158 (eg robots) or other systems known in the art. In particular, the controller 148 Send information, instructions, and / or requests to all of these systems patches related to building the shoe.

In some cases, the machine controller compares destination information from an order file (e.g., design data) with the actual data. This type of data is detected by a sensor unit which is controlled by the machine control, for example the camera system. Any sensor unit capable of determining a position (eg, optics, pressure, etc.) may be used to estimate the actual position of the patches, components, carrier surfaces (eg, ledges or topsheets), or a combination of parts to capture. The comparison is used to modify the assembly process of the outer pattern periphery to provide a more complete and accurate geometry file 94 allowing for possible distortions or deformations that may have been caused during the patch process to ensure that all subsequent patches are correctly placed.

Another illustrative example, as in 28 shown, represents the order file 146 represents the data from the material database 98 retrieves to the controller 148 To provide information. Furthermore, the geometry file 94 and / or the job file 146 Provide information to the controller to completely define a shoe, such as providing a complete description of the shoe, including geometry information, 3D information, and color and / or material specifications so that the controller can control the various elements of the patch process , Information from the controller 148 can be provided to the various machine elements or controls that are involved in the various steps of the patch process, as in 28 represented (for example, unwinding and cutting material), recording (for example recording the patches), activation, placement and consolidation.

Geometry files, job files, and / or the material database may be in the form of one or more files, including, but not limited to, DXF files, XML Files, text-based files such as text files, documents, spreadsheets, databases or any systems known in the art.

Work orders may be created by all concerned, such as a designer, a customer, a user, a trainer, or any other person interested in personalizing an article, such as a shoe. Workplaces can be created using user interfaces such as text files, spreadsheets, word processing documents, graphical user interfaces such as human interface computers, keyboards, pointing devices, mice, pointer pens, touchpads, trackballs, joysticks, etc., projection technologies (e.g., virtual projectors, virtual keyboards, virtual screens, heads-up displays), virtual reality devices and / or combinations thereof.

User choice available when creating the job file may be limited by the system that is used to create it, particularly the design files that are available in the system and the materials specified in the system. the design files and / or the material database used to create the job file.

During the creation of the job file, users may be instructed to select, for example, a specific model, size, materials, colors, labels, components, design elements, etc. For example, a user may use a user interface at home, in a shop, at a stage, during a so-called tailgate party, etc., to design a shoe according to his specifications.

Users can select from styles, components (such as stability elements, heel caps, toe caps, outsoles, studs, traction elements, extensibility elements), stiffness elements, damping elements, sizes, materials, colors, etc. to create a desired article.

As in the 29 - 30 User selections stored in the job file can be used to retrieve data from the geometry file as well as from the material database corresponding to the selections contained in the job file.

The materials database includes various processing parameters for the various materials that may be considered for use in one or more designs or designs. The values stored in the material database can come from the specification data sheets, but they can also be partially manually tested and entered for each material. For example, a temperature and time required by a particular laser may be determined to laser cut a patch, and these values may be appropriately entered into a material database for reference at a later time. Materials in the database can be identified by their shape (eg, tape, foil, string, etc.), the type of material (for example, a key code can be assigned), color, thickness, width, etc. The use of this Material ID allows to retrieve the respective processing conditions from the material database.

As in 29 can be assigned a material ID to the materials used in the article, using both the job file and the geometry file. This material ID may include, for example, a shape, a material, a color, a thickness, a width, etc. This material ID can be found in the 27 - 33 provided material database to determine the processing conditions for this material. For example, the material database 98 Also includes information on laser cutting (eg, energy, speed, cycles, focus position, etc.), infrared heat (eg, energy, duration, distance, etc.), consolidation (eg, temperature, pressure, duration, etc.), and / or any other processes , which are necessary for the production of the article.

The material database provides, for example, information relating to process parameters for various materials, such as material handling, laser cutting materials, identification of materials via optical systems, placement of materials by robots, and various other process parameters that involve handling the selected materials during assembly of an article related. Information in the material database may, in some cases, be the result of manual material testing under conditions that correspond to the conditions used in the manufacture of the shoe, for example, during welding, cutting, positioning, etc.

As illustrative examples, the list 31 Processes such as laser cutting, infrared heating and consolidation. Regarding a process such as laser cutting, the material database would be able to provide information regarding the energy of the laser, the speed of the laser, the number of cycles, the focus positions for the laser with respect to the material of interest, etc. provide. For an application such as infrared welding, the infrared database would be able to provide processing conditions such as the energy to be supplied by the infrared source, the duration over which that energy is to be delivered, a distance to the infrared source of the material to be activated set up is the number of cycles, an area of the material to be activated, how focused the energy of the infrared source is to be and / or other data relevant to IR heating. Furthermore, the material database can indicate the temperatures, duration, pressures, number of cycles required to consolidate the specific material.

32 gives a deeper insight into the interaction between the files (for example, the design files 92 , the geometry file 94 , the order file 146 , the material database 98 , the conversion software 96 , the control 148 and the systems used to perform the patch placement process. As an illustrative example, the individual instructions shown are the controls 148 issued by the system that can receive such an instruction. For example, an unwinding unit and / or transport device such as a conveyor belt can be instructed 160 to unwind the material, move the conveyor, calculate the material offset, cut, move the conveyor, and transport tape to a specified location. Identification systems can, as shown, be an optical system for picking up patches and placing patches and receiving instructions 162 include, but are not limited to, instructions for locating a patch to receive a patch (e.g., grab [sic]). Information captured by the identification system, or more specifically the optical system for acquisition and placement, may be provided, as shown, in part to the conversion software via a feedback loop. This information may, in some cases, before the conversion software is received by the controller as feedback 166 gerouted and / or processed. Further instructions 164 For example, instructions may be given to the carrier and / or the conveyor to move a carrier to a position, raise the carrier to a certain height, locate the base material, etc. Feedback 166 The conversion software may continue regarding the results of the instructions 164 to be provided.

Accordingly, the individualization of an article is made possible, including in terms of construction. For example, a customer may access a personalization tool, such as an online tool, an app, a personalization tool in the store, and / or combinations thereof. Based on the design of the article, a customer interface can present multiple variables to specify. In particular shows 30 a process for creating a personalized shoe for a user. A system user can use an online tool 170 use to specify specific items for the shoes to create an order file. As in 30 As shown, a user may select a model, size, left or right and the elements needed for each shoe. Using the custom data, a job file is created, such as a customer.csv file.

As an illustrative example, if desired, a person, such as a trainer, manager, and / or instructor, may enter data into an order file for ordering a pair of shoes for a team, such as a database or spreadsheet, to ensure that the design for all shoes remain the same while the shoes can be tailored to the players' particular needs in terms of their position in the game, orthopedic considerations, physical requirements or the like, and / or combinations thereof.

In this way, a team can behave closed with regard to their sporting goods such as shoes, uniforms, headgear, protective clothing, while at the same time taking into account the particular needs of a player, runner, swimmer, rider, skier, etc.

In some cases, particularly shoes, choices may be based on the conditions or problems a wearer has experienced and / or scans of the wearer's foot. For example, there may be pre-set solutions to common foot and / or ortophoric problems for each shoe, such as flatfoot, metatarsalgia, overpronation, underpronation, hammertoes, blisters, inflamed foot pads, corns, calluses, heel spurs, claw and claw toes, and claw toes. ingrown toenails, plantar fasciitis, etc.

Accordingly, in some cases, scans of a body part, such as a foot, may be used to tailor components or designs to the user. Scans can be done on-site or provided by an external source.

Furthermore, in some cases, diseases and / or limitations of an athlete may be used to identify components, designs, and / or patches for an article based on information from physicians, physiotherapists, occupational therapists, and / or Trainers to determine the best selection of materials, designs and / or designs for the athlete.

In particular, for a shoe design, a designer may use a 3D design application to create the design using a predefined 3D digital surface to define a digital slat of the shoe. In some cases, lines drawn in this application can be used directly for cutting materials, such as patches, placing materials, and / or other parts. For example, the designer virtually creates parts using design lines. The 3D software can produce virtual representations of the shoe and / or the materials used therein. Design files and / or work orders can be generated automatically by the 3D design program. Work orders may be used to instruct various robots, digital devices, mechanical devices, and / or combinations thereof to generate the shoe.

In some cases, sporting goods such as a shoe and / or elements of the shoe may be constructed and then used to instruct the system to make a patch object. For example, a shoe designer, manufacturer, or stylist may provide a commercially available base shoe shape using conventional techniques, or otherwise conventional footwear customary in the industry. Data regarding the shoe and / or shoe elements may be digitally detected in terms of the shape, size and / or configuration of the parts.

For example, the surface of a base shoe is accurately scanned 3D to determine the spatial coordinates xB, yB and, for example, for each point on its surface. These coordinates may be acquired using optical systems, laser scanners, laser scanning systems, mechanical measurements, or any other method known in the art, and in combination with software such as computer-aided design ("CAD") software ,

For example, a mechanical gauge may be run across the actual surface of a base shoe mold along paths that allow the shape of the shoe shape to be accurately understood. The meter is essentially a mechanical meter controlled by a computer running CAD simulation programs.

A base shoe mold is thus digitized, or reconstructed in a digital format using a 3D CAD data acquisition technique. In all cases, the result of this data collection step is a data file that can be analyzed in a 3D CAD setting. The surface of the base shoe mold in its reconstructed digital form can be reworked using the CAD program.

Furthermore, molds of sporting goods such as a base shoe mold already in digital format for CAD processing may also be used. For example, the data about such a shoe shape could be retrieved from a memory unit connected to or related to said computer means. Alternatively, the data may be retrieved from external or bulk stores, such as a database.

As in 33 can display information from the design files 92 with information from a material database 98 and / or an order file to fully define a shoe, for example, providing a complete description of the shoe, including geometry information, 3D information, and color and / or material specifications.

33 FIG. 12 shows an illustrative example of an algorithm for making an article, particularly a shoe, using 3D placement of materials. In particular shows 33 a system that operates without an optical system for placement of materials. The design file 92 is a DXF file and can be combined with a control file 172 , such as an XML file. The design file includes the specifications for a shoe model across multiple sizes. The design file can be converted to a geometry file using conversion software such as Halcon. The control file (for example, an XML file) can be created using a processor 154 be converted to a points wokle 178 using a simulation of the process of making the shoe as confirmation of the calculations. The point cloud 178 identifies locations of the robots for positioning the patches and / or components on an article, such as a shoe.

Information coming from the design file 92 and the control file 172 such as the geometry file 94 and the point cloud 178 , can be used to create a machine database 176 to create. Information from the machine database 176 , the material database 98 and from the order file 146 become a machine control 148 provided. The control 148 controls various systems required for the manufacture of the article. For example, material procurement 150 (for example, where the material is stored), material supply 152 (For example, unwinding materials, delivering materials from a storage location to where they are needed), processing 154 (for example, cutting), tracking 156 (eg optical systems), positioning systems 158 (eg robots) or other systems known in the art.

As an illustrative example, the point cloud may specify locations at which the two robots, in particular a six-axis robot and a Selective Compliance Assembly Robot Arm ("SCARA" robots) meet to facilitate patch placement. For example, a generated file may include the 3D target points. 2 points per patch (ie 1 target point for the SCARA robot and 1 target point for the six-axis robot). In some cases, the target points may be recorded with respect to the coordinate system of a robot. For example, the target points for the SCARA robot may be written with respect to the coordinate system of the six-axis robot. Simulations of any size, design and / or shoe can be made to ensure that the cloud of points is correct. The control 148 Controls how the robots move to the target. The from the controller 148 developed paths can be confirmed using simulation software.

In some cases, a processor connected to an optical system may be used to ensure correct cutting and / or placement of materials. For example, conversion software on a processor can interpret geometry files, such as a DXF file, to create and / or place patches and / or components. The production and / or placement of the patches may require further information from both the order file and the material database.

For example, one or more robots may use the data from the converted files to determine what actions need to be taken to construct an article. In particular, robots may retrieve information regarding the materials that are to be patted, the amount of vacuum to be used to accommodate a particular part, which materials to pick in terms of the geometry of the patches where the gripper component is to be moved Locations of the materials where the materials are to be deposited, etc. Further, a cutter for tailoring patch materials and / or other components may be controlled using the data provided in the conversion software. In some cases, the cutting device is a laser cutter. Other examples of a cutting device include, but are not limited to, laser cutters, dies, plasma cutters, waterjet cutters, knives, etc.

Identification systems can be used to locate, identify, and / or position parts. For example, identification systems may include optical systems, such as systems using machine optics and / or computer optics, laser scanners, etc. Methods that can be used for the localization, identification and / or positioning of parts without being limited to them, so-called "stitching" (ie the combination of adjacent 2D or 3D images), filtering (for example morphological filtering), determination of limit values, Pixel counting, segmentation (ie, partitioning a digital image into many segments to simplify and / or modify the appearance of an image so that the image becomes more meaningful and easier to analyze), in-painting, bordering, color analysis, blobbing Discovery & manipulation (that is, examining an image for discrete blobs of connected pixels as image landmarks), neural network processing (weighted and self-learning multi-variable decision making), pattern recognition including template matching, barcode reading, optical character recognition, measurement or metrology (ie Measurement of object dimensions (at in pixels, geometric coordinates, inches or millimeters)), comparison with target values to achieve a "pass or fail" or "go / no go" result and include any method known in the art or combinations thereof.

In certain embodiments, the software uses pattern recognition as schematically 21 seen. This allows the operator to move the production system to the contours of the patch 10 to be trained to exercise, as in the left half of 21 represented (for example, with a camera 30 and the physical parts 10 , or by uploading the CAD file (s)). Furthermore, during production, partially distorted parts / patches 10 may also be correctly recognized by the system, as in the right half of FIG 21 shown. You can see an optical system with one or more camera (s) showing the patches 10 identify / identify on the conveyor 12 be used for this purpose. In this context illustrate the 22a -C a graphic User interface used for pattern recognition of patches 10 different sizes and shapes is used.

Basically, the patches 10 The invention can be constructed in various forms, such as in 34 shown. Furthermore, various materials may be envisioned, which may be selected for a variety of reasons, including design, quality, utility (eg, reinforcement, breathability, durability, ease of use), or combinations thereof, as defined in this document.

In some cases, large parts can be split into smaller subgroups to identify them according to the 22b -C to improve. Accordingly, components may be divided into quadrants or sections for improved identification. This may allow for easier identification, even if there are variations in parts. Patches may then be placed relative to the quadrant or portion offset from the reference points, quadrants, and / or sections. The identification of a part may, for example, be based on the matching of a contour or an outline of a quadrant, section and / or part of a defined value.

The use of a specific combination of patches 10 may allow sporting goods with specified characteristics, such as decorative properties (unique appearance, simple, varied, special-effect tapes, visualization of automation and / or presentation of the next personalization level), reinforcing properties (local stiffening, flexible areas, changes in properties through stratification , special reinforcement tapes and / or performance personalization) as well as assembly features (actual 3D upper, no "SD detour", cutting efficiency for textile patchwork uppers and / or hot melt tape at the bottom for toolmaking). Examples are in 35 shown.

Furthermore, fine tuning can be achieved in individual zones using patches of various sizes.

For example, the in 35 For example, shoes have various configurations of patches to form a substantially unified upper. The materials used in the patches and the geometry may be selected to meet specified design requirements. Some materials may be more suitable than other materials for their various properties including, but not limited to, strength-to-weight ratio, strength in a particular direction, ductility, grip, breathability, reflectivity, etc.

Accordingly, it may be useful for some high performance sports shoes to select materials with a high strength-to-weight ratio. For example, in the design of lightweight running shoes, competitive mountaineering boots, and / or lightweight shoes, a fixed design requirement may require patching materials that have a high strength-to-weight ratio. In return, shoes that require extra stability or protection for the foot may require such materials, but may also require the use of highly resistant materials.

Further, for example, scans of a user's foot can be used to tailor the design of an upper, midsole, or outsole of a shoe to create a shoe that is personalized for both the user's foot and the specific needs of the sport the use. Accordingly, patches may be placed to reflect a geometry of the foot and / or correct for any problems that the user may have when using the shoe for a sport.

Shoe designs give the shoe designers, as in 35 represented a degree of flexibility. For example, a reduction in the weight properties through the use of positioning patches, technical implementation of ductility, the ability to make the material rigid or flexible in different directions, the technical implementation of load paths, the production of the upper material of several two-dimensional or three-dimensionally cut exactly created Patches cut from materials that meet specified specifications for the material. Furthermore, the use of patches and the methods described herein reduces or even eliminates the need for stitching and / or single piece manufacturing during shoe assembly.

It is also possible to technically improve performance in terms of controlled extensibility, breathability, orthopedics, and / or support structures, such as ankle support in the form of an insulation member such as a staple or tab using variously configured patches.

For example, those in the figures include 102 . 602 . 702 . 802 . 902 37 . 38 . 39 . 40 illustrated upper shoe constructions heel area caps made of patches 714 . 814 . 914 with a functional zone in the heel area of the shoe upper 101 . 601 . 701 . 801 . 901 , The heel cap made of patches 714 . 814 . 914 is configured to provide additional support and / or stiffness to the heel area of the user's foot. As in 42 For example, the patch heel cup may include a plurality of overlapping patches that form an overlapping structure in the heel area. The patches used can be selected to ensure that the heel cup has specific, fixed properties, such as thickness and / or stability.

Another illustrative example of a patches heel construction is in 48 shown. The patches 10 are placed around the heel and extend over areas without base material 72 and cause additional breathability in the upper 102 while providing stiffness in critical areas around the heel.

As in the 43 - 44 can be a functional region in terms of breathability 188 formed by positioning patches in a lattice-like structure in an upper. The grid-like structure may include partially overlapping patches as well as open areas. Such a breathability construction may be used in specific areas on an upper or a garment. For example, an area 188 , which is functional in terms of breathability, is placed in a forefoot area in a shoe upper construction. Furthermore, an area that is functional in terms of breathability may overlay a piece of fabric so that the piece of fabric rests against the foot of the wearer. In turn, the tissue region may be made of material that is the breathability aspects of the breathability functional region 188 further strengthened.

The 44 shows different views in the development of a railway and off-road running shoe. In 44a A design drawing is shown showing where additional support structures should be based on the design of the shoe. 44b shows a 2D image of an upper material 102 including a proportionate base material under construction. Accordingly, parts of the upper material 102 exclusively from patches 10 educated. For example, in the in 44b Pictured toe cap patches arranged so that they form the upper. The arrangement of the patches in the forefoot area creates an area 188 , which is functional in terms of breathability and is composed entirely of patches and in some areas requires no base material. Finally, the shows 44d an alternative version of a shoe constructed using an upper which is the upper 102 out 44b similar but has a complete base material.

As in 35 As shown, a structural "chassis" of a shoe may be used for a wide variety of footwear intended for a different end use and / or having preselected features. For example, a particular "chassis" that has been engineered for different applications may be associated with the outer "style", the optics, and the surface technique (eg, texture and surface feel). Based on this, it is possible to produce shoes which have a uniform appearance and a uniform surface characteristic, but are very different in terms of their "chassis tuning" or structural design, which can be used to maintain a uniform brand appearance or style , For example, the surface of a football shoe / soccer shoe may be configured by arranging certain patches to improve the grip zones of the shoe. Such as in 35 As shown, many embodiments of the present system are compatible under their respective applications, meaning that a single face design can be used for many end-uses.

Load paths on a shoe can be identified using computer assisted analysis (eg, three-dimensional analysis of finite elements, etc.) and / or physical tests. Various embodiments of footwear topsheets include placement of patches along the critical load paths of the component. The load paths may be different for different sports and article types. Accordingly, articles with multiple designs can be developed for the different sports in which they are used. As an illustrative example, a basic design may be used for both American football, rugby and football, but the patches and / or components as well as their positioning may be varied to optimize the article for a sport.

Some areas of an upper are designed to provide improved fit, for example, to accommodate the movements of the wearer's foot.

36a shows various examples of patch compositions that provide desired decorative properties. For example, patches of partially transparent tape, colored tape, a woven structure, natural materials, printed tape (using, for example, digital printing screen printing and / or sublimation printing), structured tape (for example with perforations, engravings, and / or lasered tape), different cuts (for example round, grade ), different widths and / or multi-layer tapes for laser engraving.

36b shows various examples of patch compositions that provide desired reinforcing properties. Conceivable here is the addition of one or more tape layers, the change in the direction of orientation of the tape, the use of a reinforcing tape (for example carbon fiber, glass fibers and / or ultra-high molecular weight polyethylene ("UHMWEPE"), for example Dyneema fibers), a rigid or elastic tape for bridging compression cuts in fabric and / or a multi-layer tape with different extensibility for laser engraving. Furthermore, for example, heel caps or foam pads can be provided as shown.

Various designs of flexible compositions for use on a sporting article may include multiple layers of material, for example, for continuous surface layers and / or fiber reinforced layers, and / or technical arrangements of individual patches. As in 12b As shown, multiple layers of patches can be configured to handle loads from different directions. For example, using multiple patches can give a sporting goods multi-directional load sharing capability.

Some patch placement configurations may include one or more design layers. Patches can give texture and / or color to a surface layer of a sports article. Such as in the 35 - 36b Patches can enhance the design of a shoe by adding color and / or texture to the shoe.

36c shows various examples of patch compositions that provide specified assembly properties. For example, an overlapping tape could be used to form an upper without a textile backing. Textile patches can be joined together to reduce waste and, in some cases, optimize cutting efficiency. Meltable patches can be placed at the bottom to allow connection to the midsole. The use of fusible patches can reduce a number of processing steps commonly required in the conventional manufacture of a shoe. For example, an outsole with the midsole may be utilized using a method that does not require an additional liquid adhesive application step.

In any event, the materials that may be used include, for example, polymers (eg, TPU, nylon), textiles, flocked tape, nonwoven, natural fibers, and / or leather. The adhesion between the patches 10 can be provided by means of a meltable tape material, a hot melt back and / or a hot melt fabric.

Furthermore, the patch constructions described herein can reduce and in some cases eliminate the need for sutures. Accordingly, this opens up the possibility of reducing or eliminating the need for stitching on the main load paths of the shoe design. By reducing or eliminating the number of stitches on a load path of the shoe, the durability of a particular shoe design can be maintained, which in turn can be beneficial to the design of a lightweight shoe.

The device preferably also includes a control means (not shown) which enables the manufacture of a plurality of different shoes by means of the device shown. The control means may further comprise an interface for interacting with at least one future wearer of one of the shoes to be manufactured. This allows the future wearer to tailor the shoe produced to his or her needs.

The 37 - 40 show further illustrative examples of patch configurations used to make shoes. As illustrated, the patches are arranged to provide support based on the specified specifications for a particular type of shoe. Accordingly, in some cases, the patches may be arranged in a manner similar to conventional placement of reinforcing materials. The use of patches may allow more accurate positioning of support elements, depending on the configuration of the patches, for example size and / or stability properties of the materials used.

As in 37 shown, the shoe upper 602 be constructed exclusively from patches. The patches 610 may vary in size, material, and / or orientation to form a patches-like appearance. Patches overlap depending on the configuration of the shoe partially or completely. 37 shows a plurality of overlapping patches 610 for building a shoe 600 be used.

Materials vary from region to region in the shoe to give the shoe specific characteristics. Specified properties imparted to the shoe by patches may include abrasion, strength, water resistance, breathability, resistance, flexibility, the ability to put the foot in the correct position for a particular sport, as well as support for the muscles during exercise, etc. include.

Patches and / or components may be applied to both sides of a support surface. For example, patches may be applied to a 2D support surface such as an upper on a side corresponding to the interior of the shoe and on the side corresponding to the exterior of the shoe. As an illustrative example, damping patches may be applied on the inside, and patches that increase grip may be applied to the outside.

The placement of patches and / or components on a 3D support surface can also be done on both the inside and the outside. For example, patches may be applied to an outer surface of a 3D engineered upper while placed on a last. The upper can be removed from the last, and additional patches and / or components can be placed on the inside of the upper.

Patches can be used to secure components to a support surface and / or to secure multiple support surfaces together. For example, it may be desirable for the carrier surface to have different properties along the length of the article that may require different carrier surfaces. These different carrier surfaces can be joined by means of patches and / or components. In particular, patches can be used to bond carrier surfaces together.

As in 41 For example, one illustrative example of a shoe upper construction includes placing patches 10 on a two-dimensional support surface 22 (2D application of patches). As shown, multiple patches may be used and texturing may be used in varying degrees across the upper. Areas where stretchability is desired may include patches of lesser thicknesses / widths and / or engraving. Areas where additional stability is desired include overlapping patches, such as in the heel area 714 of the 38 shown.

Furthermore, the show 5 and 41 an example of a cap member 180 for use in the forefoot, the toe cap variable extensibility due to an engraved pattern 66 lends that in some areas a toe cap element 180 different slat depths 64 includes. As in 41 You can see different engraving patterns 66 can be used on patches to stretch in some stretch areas 182 to improve. Some areas of the upper can have multiple patches 10 include, which are arranged on top of each other in these stability areas 184 to improve the stability. The toe cap element 180 from the 41 can provide more stability on the medial side than on the lateral side, which may be desirable in some applications.

In some cases, the intermediate product is sewn into a 3D construction. Patches may be placed based on the use of the shoe, the desired properties of the shoe (eg, water repellent, breathable, supportive, etc.), needs of the wearer, and / or design considerations.

Alternatively, the resulting intermediate can be placed on a last and put into final form.

In some cases, patterns may be formed by patching, printing, positioning smaller elements on the patch, etc., using a patch. Such positive reinforcements may be arranged to impart certain characteristics to the patch and / or the article construction. For example, a patch can be stiffened by selectively printing, depositing, and / or applying patches to the surface.

38 shows an example of a shoe 700 with a substrate 708 on the patches 710 strategically placed to give the shoe certain characteristics. Placing the patches can simply affect the positioning and / or attachment of the patches. The attachment can be the result of a frictional connection, gluing or static forces. Patches 710 in the heel area 712 are arranged so that they overlap so as to have a heel counter 714 to build. patches 710 become in the midfoot area 716 used to support the midfoot. As shown, patches can 710 over the shoe from the midfoot area 716 to the heel area 712 extend.

A soccer shoe 800 with an upper 802 with patches and an outsole, the studs 822 on a sole plate 818 includes, is in 39 shown. The sole plate 818 also includes the heel counter 820 , Patches are placed on the shoe, especially where additional support is required. For example, the patches 810 arranged so that they are the front heel counter 820 So provide support so that a heel cap made of patches 814 is formed.

Alternatively, some embodiments may use an outer material comprised of conventional materials, knitted or woven materials, nonwoven materials, leather, synthetic materials, or the like in combination with patches / elements placed to form the midsole and / or outsole.

As in 40 pictured, has a basketball shoe 900 specific structural requirements. The patches 910 be on the shoe 900 placed where additional support effect is required. For example, as in 40 shown, patches arranged around an ankle position to the support structure 924 to build. The support structure 924 can provide additional support for the ankle and foot. For basketball as well as other lateral sports (for example, tennis, American football, football, etc.), it may be particularly helpful if additional support is provided at the front and / or in the area of the upper leather 926 given is. As shown, at least some patches cover 910 a part of the upper 902 and extend to the midsole 904 , The patches on or near the upper leather 926 can be selected so that they have a certain abrasion resistance. For example, upper leather sections on the medial side may be exposed to very heavy abrasion in use and may require correspondingly increased abrasion resistance.

In certain cases, the patches may 10 down to the outsole 6 extend, as in 45 is shown. The patches arranged in this way provide added stability, fit and / or traction benefits to the shoe. For example, a patch having a flexible region may have a TPU layer of less than 0.5 mm. In particular, a TPU film having a thickness of about 0.3 mm can be used in areas that need to be flexible. In contrast, in areas that require stability, patches with a thickness greater than 0.5 mm can be used. In some cases, patches greater than 0.7 mm thick may be used. Patches and / or patch constructions that add traction to the shoe may be arranged to contact a portion of the midsole. As in 5 As illustrated, patches 10 may extend from the upper over the midsole and over the outsole 6 extend and another part of the outsole 6 ' ingest, take an end of the patches 10 covered.

As in 45 represented, the patches can 10 be placed on the midsole. Patches placed on the midsole can be used to control midsole properties. For example, patches may be placed in a portion of the midsole to control shear forces in the midsole. For example, for many lateral sports, patches can be selectively placed on the midsole to reduce shear effects.

The use of patches on the midsole can increase the stability of the foot. For example, patches on the midsole can cause the foot to have better stability.

Patches on the midsole can provide protection against wear. For example, patches can provide abrasion and / or fouling resistance to a midsole.

In some cases, patches can be placed on the midsole to increase flexural stiffness in defined areas.

Other constructions that support different elements are in the 46 - 47 shown. In some cases, patches can be used to reinforce laces. Furthermore, patches can be placed along areas of the shoe that require additional support, as in 47 shown. The in 47 shoe shown 101 provides stability in the metatarsal area and in the upper area. All patches and placements may be personalized in accordance with the disclosure herein to meet the needs and desires of an end user.

The 49 and 50 show patches 10 which are capable of having very different stability levels in different areas of the shoe 101 to provide as needed. For example, locations with nodes 12 would generally provide more stability than areas with extended links 14 provided that the patches are of the same material and are the same thickness. Furthermore, there would be distances between the nodes 12 influence the stability of an area of an upper material in general. For example, as in 49 shown, knot near the collar region 190 , the Ösenregion 194 and the heel region 196 be concentrated to give these areas more stability. 51 shows a 2D upper 102 with patches drawn on one side to show areas of concentration of nodes for increased stability.

Further, in some instances, an upper may include multiple base materials in different portions of the upper to impart the desired properties to the shoe. These multiple base materials can be joined using patches and / or components.

As in 52 shown includes a football boot 101 patches 10 with different functionality in different areas. For example, the grip patches 198 be placed anywhere in the shoe, where a high ball contact takes place. Abrasion resistant patches 246 are provided in areas where the shoes are exposed to strong contact and / or wear. Highly flexible patches 248 are provided in areas that require additional flexibility and / or ductility. Stability patches 250 Provide additional stability in areas designed to provide additional stability to the user. Furthermore, additional patches for additional functionalities can be made available, for example for water repellency, reinforcement, damping, insulation, design, etc.

In some instances, outsole elements may be cut out of material, such as one of a sheet of material or a roll of material placed on a midsole and / or part of an outsole. As in 53 shown are outsole elements 1028 by means of a cutting device 1007 from a roll of material 1005 using a unwind unit 1032 cut out. Outsole elements are from a transport device 1030 by means of the gripping device 1015 recorded and, for example, using an infrared source 1017 , as in 53 shown, activated. For example, in some instances, outsole elements may be coupled to the sole, midsole, and / or outsole using heat, adhesive, mechanical closure, and other methods known in the art.

In some cases, outsole elements and / or damping elements may be provided fully formed for the system and placed on a midsole and / or an upper. An illustrative example shows in 75 preformed damping elements 2060 which can be coupled with an upper material immediately after activation. These damping elements can be arranged independently of each other in such a way that the elements are connected to another surface only on the surfaces which are in contact with the upper material. As shown, the damping elements 260 an outsole element 62 on the surface, which comes into contact with the ground. The damping elements can act as a midsole. Damping elements may comprise expanded particulate foams such as eTPU and / or ePEBA, expanded foams including EVA or the like.

In some instances where outsole elements are used, an outsole element may be involved with a composition containing a fusible material, a hot melt layer, a hot melt tissue, mechanical elements such as protrusions, screw elements, and / or recesses.

In some cases outsole elements may be textured using a texturing device if desired by means of the cutting device, for example a laser cutter. Alternatively, exterior elements can be textured either before or after cutting. In other cases, outsole elements may be pre-fabricated and provided to the system. 54 shows an outsole element 1128 which may be placed on a sole, a midsole and / or added to an outsole so as to form the outsole or a portion thereof. As in 54 As shown, the materials to be placed may include irregular shapes. Outsole member configurations may vary based on the use of the shoe and / or needs of the wearer.

As the illustrative example in 55a and in 55b shows, a positioning device such as a gripping device 1215 used to be an outsole element 1228 . 1229 on the shoe 1200 to place. As in 55 shown can be an outsole element 1228 . 1229 be a substantially flat element. Furthermore, outsole elements can be placed directly on the midsole. In other cases, an outsole element may be a bolt, as in FIG 55b shown.

In some cases, the outsole elements may include damping elements such as studs, bolts, staples, or pins with a claw or rebound geometry.

Materials for the outsole elements include, but are not limited to, thermoplastic polymers such as TPU, PA12, etc, composites such as thermoplastic matrix materials, Rubber, for example a rubber component with a thermoplastic adhesive on at least one side and / or combinations thereof. In certain cases, the outsole may be constructed of metal.

Outsole elements may, as in 55a shown to be flat. In some cases, outsole elements may be layered to increase the height of the outsole. For example, flat outsole elements may be combined with bolts to increase the height of the outsole in a particular area.

Shoes made using patches can be prefabricated in current production, and an outsole then applied as needed in the store or near the point of sale.

As in the 57 - 59 shown, reject the shoes 101 many outsole elements 62 with patches that extend from the outsole to the upper.

For example, as in 59 shown the grip patches 198 be placed anywhere in the shoe, where a high ball contact takes place. Abrasion resistant patches 246 are provided in areas where the shoes are exposed to strong contact and / or wear. Highly flexible patches 248 are provided in areas that require additional flexibility and / or ductility. Stability patches 250 Provide additional stability in areas designed to provide additional stability to the user. Furthermore, additional patches for additional functionalities can be made available, for example for water repellency, reinforcement, damping, insulation, design, etc.

In some cases, patches can be applied to an upper, a midsole and an outsole. Especially for sports with lateral movements such as tennis, basketball, etc., additional stability can be provided in the forefoot region with patches that wrap around the shoe, as in 12 shown.

As in 56 shown, can be a midsole 1304 As used herein, any material including, but not limited to, particulate foams such as eTPU, foamed polymers such as EVA, PU, solid polymers (e.g., PA12, TPU), and / or combinations thereof. Midsoles can be made using a gripping device 1315 as in 56 be arranged shown.

As in the 60 - 73 Patches can also be used in clothing for support. The illustrative examples in the 60 - 61 show an example of a shirt 1440 and a brassiere 1542 , Other examples of bras are in the 62 - 64 shown. As can be seen from the various examples, the configurations of the patches 1410 . 1510 . 1610 . 1710 . 1810 on the textiles 1444 . 1544 . 1644 . 1744 . 1844 vary depending on the needs of the wearer, as there are a variety of different body shapes with different levels of support, comfort, breathability, etc.

Furthermore, patches can be used to give garments important properties. For example, patch designs can be layered with multiple patches to give certain features to the garments in specified areas. The 3b - 3t show multi-layered patches that are able to impart certain properties to the articles that are selected by either a designer or a user. Properties that are affected by such patches include breathability, insulation, stability, cushioning, windbreak, splash protection, design, reflectivity, etc.

The 65 - 73 show various examples of configurations with patches on clothing items. As in the 71 and 72 shown, the patches can 10 be placed so that they correspond to the muscle groups of interest.

73 shows a patch configuration in a sleeve that allows mobility of the arm. In this way, patches can be placed that promote movement in certain directions while limiting movement in other directions.

For example, patches based on data provided by an athlete, observation data, and / or scan data may be placed on clothing to enhance the athlete's shape based on the requirements of the sport of interest. In some cases, this may require asymmetric positioning of patches to promote a sport-specific movement such as baseball, tennis, baseball or golf.

Further, user information, such as weaknesses due to, for example, injury may be used to identify areas on a garment where special support may be required, such as in the area of joints. For example, in 71 shown a reinforcement around a knee area, with which the knee receives additional support.

The method described above can also be used as a way to personalize sporting goods such as shoes, clothing, rackets, sticks, balls and batons to meet the needs of the user / wearer.

In the case of footwear and apparel, the information collected by the user to create, but not limited to, a shoe or article includes information that the user enters directly and / or that is stored in a database. User data of interest may include, but is not limited to, information regarding clothing size, such as measurements that are stored, for example, in a database by a user, by the user or another person, such as a store operator captured, 3D scans and combinations thereof. A user may input or have inputted this information to a computing device, such as a computer, mobile phone, etc., which somehow connects to a production device to create the shoe or garment.

Further, users may be prompted to enter data regarding their preferred fit, activities, injuries, pain experiences, so that the system and / or a human operator may suggest configurations based on the needs of the user. Accordingly, a customer may seek advice on appropriate shoe models, apparel articles, or suitable patch configurations, and / or the customer may individually design a desired shoe model or garment.

Similar information can be entered for the manufacture of sports articles, such as rackets, sticks, balls and batons. Furthermore, it may be desirable to input information about a player's position, average strokes, swing modes, etc. This information, in combination with the user data described above, enable the production of user-specific sports articles.

74 shows a vivid example of the possibilities of producing a ball from a series of patches, which are arranged on a support, in this case a ball bubble or a structural element, for producing a textile layer of the ball. Further, in some instances, patches may be used to form a body or structural elements, a foam layer and / or outer layer of the ball.

Articles made using this method for placing patches and / or components may have small tolerances for positioning accuracy. Some embodiments may have a positioning tolerance for patches that is less than 1 mm between the various patches, components, and / or base material. In some cases it may be possible to work with a positioning tolerance for the patches of less than 0.5 mm. Further, as an illustrative example, upper materials were produced which accurately positioned patches within 0.1 mm tolerance. In particular, it is possible to match engravings on a first patch with those on a second patch so as to ensure that an appearance and / or physical effect is uniform. For example, apertured patches may be strung in a multi-layer configuration such that the apertures are stacked in such a manner that an aperture extends through the entire material.

The use of such a placement method can further reduce the burden on the material as the number of steps required to make an article is reduced. For example, a conventionally constructed shoe upper may require multiple process steps to build the upper, while with the placement method described herein, a single consolidation may be used to secure the upper and its components after the first placement and / or coupling of the materials. By reducing the number of steps required, as well as the amount of heat applied, the stress potential for the patches and / or components on the upper decreases during the manufacture of the upper.

The placement method described herein can further significantly reduce the amount of waste compared to conventional construction methods. Reductions can be achieved by more accurate placement and cutting of material. Furthermore, by using the local placement method, the material requirement, for example with regard to liquid adhesives, can be drastically reduced.

The method described above can also be used on a mobile sales stand, wherein the mobile sales stand one or more devices for the execution an exemplary embodiment according to the invention. Furthermore, a counseling booth can be provided where a customer can seek advice on suitable shoe models, or the customer can individually design a desired shoe model or article of clothing. According to the design of the desired shoe model, the production device can be commissioned, via the control means described above, for example, with the production of the shoe model designed by the customer.

The mobile sales stand can be used, for example, at trade fairs, major events, sports events, etc. For example, the mobile stand can be set up at a sporting event and equipped with designs that match the defined sport and are available for personalization by customers. Design elements specific to a venue, event or the like may be available in the mobile booth for the construction of the item. For example, customers may select a theme-specific design and customize it for their particular use and / or anatomy. In some cases, the item may be manufactured during the event and picked up by the customer after the event. For example, customers watching a game, running a marathon, skiing for a day, or the like, could drop by the mobile booth before leaving and picking up their items, such as clothing, shoes, and balls, ready for use.

In some cases, customers can pre-select their personalization so that customers can pick up their items at the mobile booth.

However, it is also conceivable that the mobile sales booth is placed in a department store. Furthermore, an embodiment of a sales transaction with a device for an embodiment of an exemplary embodiment of a method according to the invention is conceivable.

Finally, the above-explained embodiments for the manufacturing method can also be used in a business scenario in which the customer himself designs a sporting article and then places an order for the designed article. For example, a customer may use a graphical user interface provided on a manufacturer's or distributor's website for the design process as well as for a subsequent business transaction. The design data resulting from the customer inputs are then provided to a production device as explained above, for example in an at least partially transparent container, as explained above. The apparatus then produces the sporting article by the method explained above based on the design data individually selected by the customer.

Regardless of which specific device is used, the production process can be captured with a camera and possibly sent to the customer or any other recipient via the Internet or social networks. In some embodiments, the customer may be able to track the production of their personalized sports product in real time, resulting in a unique customer experience and / or even giving the customer the opportunity to intervene if the design of the resulting article does not meet his expectations equivalent.

• 1. Ein durch einen Nutzer personalisierter Sportartikel mit Zonen mit durch Eingaben durch einen Nutzer definierten Eigenschaften.
• 2. Ein Verfahren für die Herstellung eines personalisierten Schuhs, umfassend: Bereitstellung eines Schuhdesigns in einer Datei; Bereitstellung der Schuhdesigndatei an einen Computer, der in der Lage ist, die Schuhdesigndatei in einen Produktionsplan zu konvertieren; Bereitstellung von Elementen für die Herstellung des Schuhs; Verwendung des Produktionsplans für die Anweisung eines oder mehrerer Vorrichtungen; und Steuerung wenigstens einer der einen oder mehreren Vorrichtungen zur Herstellung des Schuhs gemäß dem Produktionsplan. Die Schuhdesigndatei kann durch einen Designer (intern oder extern) bereitgestellt werden, vorausgesetzt, dass die Formatierung korrekt ist. Beispielsweise können externen Designern Strukturen und/oder Syntax bereitgestellt werden, die für die Designdatei erforderlich ist bzw. sind. Grundsätzlich könnten Kunden einen Schuh von Grund auf designen. Ein Nutzer/Designer könnte eine vorher definierte Software verwenden, um eine Designdatei auf Grundlage der Beschränkungen der Software zu generieren. Weiterhin ist die Verwendung von Körper-Scan-Daten denkbar, um das Schuhdesign zu generieren.
• 3. Das Verfahren aus Beispiel 2, weiter umfassend die Bereitstellung von nutzerdefinierten Spezifikationen für den Schuh an den Computer, um die Erstellung des Produktionsplans zu vereinfachen.
• 4. Das Verfahren nach Beispiel 3, wobei die nutzerspezifizierten Spezifikationen teilweise unter Verwendung von Körper-Scan-Daten eines Nutzers generiert wurden.
• 5. Das Verfahren gemäß einem der voranstehenden Beispiele, wobei eine oder mehrere Vorrichtungen wenigstens ein optisches System, eine Schneidvorrichtung, einen Roboter und eine Aktivierungsvorrichtung umfasst bzw. umfassen.
• 6. Ein Verfahren für die Herstellung eines personalisierten Sportartikels, umfassend: Bereitstellung einer oder mehrerer Designdateien, die den Sportartikel beschreiben; Bereitstellung einer nutzerdefinierten Spezifikation auf Grundlage der einen oder mehreren Designdateien; Verwendung der nutzerdefinierten Spezifikation für die Modifikation der einen oder mehreren Designdateien für die Bildung einer Geometriedatei; und Positionierung der ausgewählten Materialien auf Grundlage der Geometriedatei für den Aufbau des Sportartikels.
• 7. Das Verfahren gemäß Beispiel 6, wobei der Sportartikel wenigstens einen Ball, Schläger oder Stock umfasst.
• 8. Ein personalisierter Sportartikel, umfassend: eine Trägeroberfläche (beispielsweise ein Leisten oder eine flache Oberfläche, wobei Patches platziert und dann entfernt werden, um beispielsweise das Schuhobermaterial zu bilden); und eine oder mehrere auf der Trägeroberfläche angeordnete Komponenten.
• 9. Der personalisierte Sportartikel gemäß Beispiel 8, wobei wenigstens eine der einen oder mehreren Komponenten entlang einer Kraftlinie des fertigen Sportartikels angeordnet ist.
• 10. Der personalisierte Sportartikel gemäß einem der voranstehenden Beispiele, wobei die eine oder mehrere Komponente/n ein Patch umfasst bzw. umfassen, das an einem Übergangspunkt zwischen den zwei Zonen auf dem fertigen Sportartikel angeordnet ist und wobei das Patch ein graviertes Muster aufweist oder aus einem Material gebildet ist, das einen graduellen Übergang zwischen den beiden Zonen ermöglicht.
• 11. Der personalisierte Sportartikel gemäß einem der voranstehenden Beispiele, wobei die eine oder mehreren Komponente/n mehrere Patches umfasst bzw. umfassen, so dass eine Expansionszone gebildet wird.
• 12. Der personalisierte Sportartikel gemäß einem der voranstehenden Beispiele, wobei die eine oder mehreren Komponente/n mehrere Patches umfasst bzw. umfassen, so dass eine Stützzone gebildet wird.
• 13. Der personalisierte Sportartikel gemäß einem der voranstehenden Beispiele, wobei die eine oder mehreren Komponente/n mehrere Patches umfasst bzw. umfassen, so dass eine Expansionszone gebildet wird.
• 14. Der personalisierte Sportartikel gemäß einem der voranstehenden Beispiele, wobei die eine oder mehreren Komponente/n wenigstens zwei Komponenten umfasst bzw. umfassen und die wenigstens zwei Komponenten so angeordnet sind, dass die Genauigkeit [sic: Abweichung] der wenigstens zwei angeordneten Teile weniger als etwa 1 mm beträgt und vorzugsweise weniger oder gleich 0,1 mm beträgt.
• 15. Der personalisierte Sportartikel gemäß einem der voranstehenden Beispiele, wobei die Trägeroberfläche ein Merkmal umfasst und die eine oder mehreren Komponente/n auf der Trägeroberfläche im Hinblick auf das Merkmal so angeordnet sind, dass eine Genauigkeit [sic: Abweichung] relativ zu dem Merkmal weniger als 1 mm beträgt, vorzugsweise weniger oder gleich 0,1 mm.
• 16. Ein Verfahren für den Transport flexibler Materialien, umfassend: Bereitstellung wenigstens einer Greifvorrichtung, konfiguriert für den Kontakt mit einem flexiblen Material; und Bereitstellung einer Adapterplatte, die in der Lage ist, die Greifvorrichtung mit wenigstens einem zweiten Greifvorrichtung, einem Wärmelement oder einer elektrostatischen Ladevorrichtung zu koppeln.
• 17. Das Verfahren nach Beispiel 16, wobei die Greifvorrichtung einen Coanda-Greifer oder einen anderen hierin offenbarten Greifer umfasst.
• 18. Das Verfahren nach einem der voranstehenden Beispiele, wobei eine flexible Komponente mit der Greifvorrichtung verbunden und so konfiguriert ist, dass sie sich an eine Oberfläche anpasst, auf die das flexible Material zu platzieren ist.
• 19. Das Verfahren nach einem der voranstehenden Beispiele, wobei die wenigstens eine Greifvorrichtung unter Verwendung der Adapterplatte mehrere zusammen gekoppelte Greifvorrichtungen umfasst.
• 20. Ein Verfahren für die Herstellung von personalisierten Sportartikeln aus flexiblen Teilen: Empfang einer Designspezifikation des zu produzierenden Sportartikels, insbesondere eine Datei; Bereitstellung der in der Designspezifikation spezifizierten Komponenten. automatische Generierung eines Produktionsplans auf Grundlage der Designspezifikation; und Bereitstellung eines Referenzmusters an ein System; Vergleichen der bereitgestellten Komponenten mit dem Referenzmuster; automatische Aktualisierung des Produktionsplans auf Grundlage der Designspezifikation und dem Vergleich des Referenzmusters mit den bereitgestellten Komponenten; und Durchführung des Schritts der Platzierung der Mehrzahl von Komponenten im Einklang mit dem aktualisierten Produktionsplan.

Further examples of additional aspects of the invention are shown below:

• 1. A user-personalized sporting goods with zones with user-defined properties.
• 2. A method of making a personalized shoe, comprising: providing a shoe design in a file; Providing the shoe design file to a computer capable of converting the shoe design file into a production plan; Providing elements for the manufacture of the shoe; Use of the production plan for the instruction of one or more devices; and controlling at least one of the one or more devices for manufacturing the shoe according to the production plan. The shoe design file can be provided by a designer (internal or external), provided the formatting is correct. For example, external designers may be provided with structures and / or syntax necessary for the design file. Basically, customers could design a shoe from the ground up. A user / designer could use pre-defined software to generate a design file based on the limitations of the software. Furthermore, the use of body scan data is conceivable to generate the shoe design.
• 3. The method of Example 2, further comprising providing user-defined specifications for the shoe to the computer to facilitate creation of the production plan.
• 4. The method of Example 3, wherein the user-specified specifications were generated in part using a user's body scan data.
• 5. The method of any one of the preceding examples, wherein one or more devices comprise at least one optical system, a cutting device, a robot, and an activation device.
• 6. A method for producing a personalized sports item, comprising: providing one or more design files describing the sporting item; Providing a user-defined specification based on the one or more design files; Using the user-defined specification to modify the one or more design files to form a geometry file; and positioning the selected materials based on the geometry file for building the sports article.
• 7. The method of Example 6, wherein the sporting article comprises at least one ball, racket or stick.
• 8. A personalized sporting article comprising: a support surface (eg, a last or a flat surface, with patches placed and then removed to form, for example, the shoe upper); and one or more components disposed on the support surface.
• 9. The personalized sporting article of Example 8, wherein at least one of the one or more components is disposed along a line of force of the finished sports article.
• 10. The personalized sporting article according to any one of the preceding examples, wherein the one or more components comprise a patch disposed at a transition point between the two zones on the finished sporting article, and wherein the patch comprises or comprises an engraved pattern a material that allows a gradual transition between the two zones.
• 11. The personalized sporting article of any of the preceding examples, wherein the one or more components comprise multiple patches to form an expansion zone.
• 12. The personalized sporting article according to any one of the preceding examples, wherein the one or more components comprise multiple patches to form a support zone.
• 13. The personalized sporting article of any of the preceding examples, wherein the one or more components comprise multiple patches to form an expansion zone.
• 14. The personalized sporting article according to any one of the preceding examples, wherein the one or more components comprise at least two components and the at least two components are arranged such that the accuracy of the at least two arranged parts is less than is about 1 mm and preferably less than or equal to 0.1 mm.
• 15. The personalized sporting article according to any one of the preceding examples, wherein the carrier surface comprises a feature and the one or more component (s) on the carrier surface are arranged with respect to the feature such that accuracy is less relative to the feature than 1 mm, preferably less than or equal to 0.1 mm.
• 16. A method for transporting flexible materials, comprising: providing at least one gripping device configured to contact a flexible material; and providing an adapter plate capable of coupling the gripping device to at least one second gripping device, a heating element or an electrostatic charging device.
• 17. The method of Example 16, wherein the gripping device comprises a Coanda gripper or other gripper disclosed herein.
• 18. The method of any one of the preceding examples, wherein a flexible component is connected to the gripping device and configured to conform to a surface to which the flexible material is to be placed.
• 19. The method of any one of the preceding examples, wherein the at least one gripping device using the adapter plate comprises a plurality of gripping devices coupled together.
• 20. A method of manufacturing personalized sports articles from flexible parts: receiving a design specification of the sports article to be produced, in particular a file; Provision of the components specified in the design specification. automatic generation of a production plan based on the design specification; and providing a reference pattern to a system; Comparing the provided components with the reference pattern; automatic updating of the production plan based on the design specification and comparison of the reference pattern with the provided components; and performing the step of placing the plurality of components in accordance with the updated production plan.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 8567469 B2 [0006]
• US 2014/0134378 A1 [0006]
• US 5427518 [0006]
• US 8371838 B2 [0006]
• US 7182118 B2 [0006]
• US 2005/0061422 Al [0006]

Claims (24)

Process for the manufacture of sports articles, in particular shoes, comprising the following steps: a. Provide ( 100 ) a plurality of components ( 10 ) in one of a plurality of predefined forms; and b. Place ( 400a . 400b ) of the plurality of components ( 10 ) on a two-dimensional or three-dimensional support surface ( 20 ) for producing the sports article or a part thereof. The method of claim 1, wherein the plurality of components ( 10 ) has at least one of the following: a patch; A structural element, such as a heel cap, cage, support structure, tube or strap; An outsole component, such as a bolt, tab, outsole or outsole member; An eyelet reinforcing element; A midsole element; A closure mechanism, such as laces, a lace structure or a Velcro closure system; An electrical component such as a near field communication (NFC) chip, a radio frequency identification (RFID) chip, a motor, a chipset, an antenna, a microchip, an interface, a light source, a line, a circuit Energy harvesting element and / or a battery; A sensor, such as an accelerometer, a magnetic field strength meter, or a location sensor, such as a Global Positioning System (GPS) sensor; A mechanical component; - or any combination thereof. The method of claim 1 or 2, wherein the step of providing ( 100 ) of the plurality of components ( 10 ) using a configurable cutting device ( 7 ) for cutting a plurality of patches. The method of claim 3, wherein the configurable cutting device ( 7 ) has at least one laser source, a knife, a die, a water nozzle, a heating element, a solvent, or any combination thereof. The method of claim 3 or 4, wherein the configurable cutting device ( 7 ) comprises a laser source and means for controlling movement of a laser beam emitted by the laser source, the means preferably comprising at least one mirror. The method according to any one of the preceding claims, comprising the further step of consolidating ( 500a . 500b ) of the plurality of components ( 10 ) using heat and / or pressure for a predefined period of time. The method of claim 6, wherein the step of consolidating ( 500a . 500b ) at least temporary application of a preferably made of silicone flexible membrane ( 25 ) to the plurality of components ( 10 ) having. The method of claim 7, wherein the flexible membrane ( 25 ) before applying to the majority of components ( 10 ) is substantially flat or preformed to substantially conform to the contour of the sports article to be made. The method according to any of the preceding claims 7 or 8, comprising the further step of applying pressure to the plurality of components ( 10 ) with the flexible membrane applied thereto ( 25 ) having. The method of any one of the preceding claims, wherein the step of providing ( 100 ) of the plurality of components ( 10 ): Providing material from a coil ( 5 ), a tape, a tray and / or a stack on a transport device ( 12 ); Cutting the majority of components ( 10 ) from the material using a cutting device ( 7 ); and removing excess material from the transport device ( 12 ) in an automated manner, preferably using a second coil ( 27 ). The method of any one of the preceding claims, wherein at least one of the plurality of components ( 10 ) and / or the carrier surface has a coupling mechanism such that an electrostatic force, a chemical and / or a mechanical closure between at least two of the plurality of components ( 10 ) or a part of the sports article. The method of claim 11, wherein the coupling mechanism comprises at least one electrostatic force, a hot melt adhesive, a solvent based process, a hook and loop fastener, or any combination thereof. The method of any one of the preceding claims, comprising the further step of activating ( 300 ) at least one of the components ( 10 ), preferably by heating. The method of the preceding claim, wherein the step of activating ( 300 ) activating an adhesive component of at least one of the plurality of components ( 10 ), preferably by heating. The method of any one of the preceding claims, wherein the step of placing ( 400a . 400b ) of the plurality of components ( 10 ) from an automated gripping device ( 15 ) containing one or more grippers ( 15a ) is carried out. The method according to any of the preceding claims, wherein the two-dimensional support surface ( 20 ) comprises a worktop or a substantially flat base material, such as a knitted material or a midsole; and / or wherein the three-dimensional support surface ( 20 ) comprises a working form, such as a last, or a base material carried on a working form. The method of any one of the preceding claims, wherein the plurality of components ( 10 ) comprises at least one patch comprising material selected from the group consisting of: metal, polymer, such as polyurethane, for example, thermoplastic polyurethane, nylon, foam, such as expanded foam, particulate foam, textile material, for example, a knitted, nonwoven fabric; , woven or similar material, hook and loop material, synthetic leather, coated material, transparent material, dyed material, printed material, structured material, natural fiber, for example silk, wool, hair such as camel hair, cashmere, mohair, or the like, cotton, flax, jute, kenaf, ramie, rattan, hemp, bamboo, sisal, coconut fiber, or the like, leather, suede, rubber, a woven structure, or any combination. The method of any one of the preceding claims, wherein the plurality of components ( 10 ) has a plurality of patches arranged in a manner to provide characteristics such as reinforcement, breathability, visibility, color, durability, traction, flexibility, thermoplasticity, adhesion, water repellency, water resistance, weight distribution, or any combination thereof. The method of any one of the preceding claims, comprising the further steps of: receiving ( 600 ) a design specification of the sports article to be produced, in particular a computer aided design (CAD) file; automatic generation ( 700 ) of a production plan based on the design specification; and performing ( 800 ) of the step of placing ( 400a . 400b ) of the plurality of components ( 10 ) according to the production plan. The method of any one of the preceding claims, further comprising identifying at least one of the plurality of components ( 10 ) by an image processing means ( 30 ) before performing the step of placing ( 400a . 400b ) of the plurality of components ( 10 ) having. The method of any one of the preceding claims, further comprising identifying the support surface by image processing means ( 30 ) and providing positioning data to a controller for adjusting the placement of at least one of the plurality of components. The method of claim 19-21, wherein said automatically generating ( 700 ) of a production plan based on the design specification further comprises generating a point cloud for positioning at least one of the plurality of components on the support surface. The method of any one of the preceding claims, wherein the method is performed within a moving container, wherein the movable container is preferably at least partially transparent. Sports article, in particular shoe, or part thereof, which has been produced by using a method according to any one of claims 1-23.

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